3D PRINTING THE GAME CHANGER

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PROJECT
SUBMITTED BY,
Shilpa Rachal varghese
V. A Sulfa Shukoor

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3D PRINTING A GAME-CHANGER??

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SUMMARRY
The term 3D printing covers a variety of processes in which material is joined or
solidified under computer control to create a three-dimensional object, with
material being added together (such as liquid molecules or powder grains being
fused together), typically layer by layer. In the 1990s, 3D printing techniques
were considered suitable only for the production of functional or aesthetical
prototypes and a more appropriate term was rapid prototyping. Today, the
precision, repeatability and material range have increased to the point that some
3D printing processes are considered viable as an industrial production
technology, whereby the term additive manufacturing can be used synonymously
with 3D printing. One of the key advantages of 3D printing is the ability to
producevery complex shapes orgeometries, and a prerequisite for producing any
3D printed part is a digital 3D model or a CAD file.
The most commonly used 3D Printing process is a material extrusion technique
called fused deposition modelling (FDM). Metal Powder bed fusion has been
gaining prominence lately during the immense applications of metal parts in the
3D printing industry. In 3D Printing, a three-dimensional object is built from a
computer-aided design (CAD) model, usually by successively adding material
layer by layer, unlike the conventional machining process, where material is
removed from a stock item, or the casting and forging processes which date to
antiquity.
The term "3D printing" originally referred to a process that deposits a binder
material onto a powderbed with inkjet printer heads layer by layer. More
recently, the term is being used in popular vernacular to encompass a wider
variety of additive manufacturing techniques. United States and global technical
standards use the official term additive manufacturing for this broader sense

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3D PRINTING
3D printing or additive manufacturing is a process of making three dimensional
solid objects from a digital file. The creation of a 3D printed object is achieved
using additive processes. In an additive process an object is created by laying
downsuccessivelayers ofmaterial until the object is created. Each ofthese layers
can be seen as a thinly sliced horizontal cross-sectionof the eventual object. 3D
printing is the opposite of subtractive manufacturing which is cutting out /
hollowing out a piece of metal or plastic with for instance a milling machine. 3D
printing enables you to produce complex (functional) shapes using less material
than traditional manufacturing methods.
TECHNOLOGYUSED
 Stereolithography (SLA)
The most commonly used technology in this processes is Stereolithography
(SLA). This technology employs a vat of liquid ultraviolet curable photopolymer
resin and an ultraviolet laser to build the object’s layers one at a time. For each
layer, the laser beam traces a cross-section of the part pattern on the surface of
the liquid resin. Exposure to the ultraviolet laser light cures and solidifies the
pattern traced on the resin and joins it to the layer below.
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
the part, re-coating it with fresh material. On this new liquid surface, the
subsequent layer pattern is traced, joining the previous layer. The complete three
dimensional object is formed by this project. Stereolithography requires the use
of supporting structures which serve to attach the part to the elevator platform
and to hold the object because it floats in the basin filled with liquid resin. These
are removed manually after the object is finished.

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This technique was invented in 1986 by Charles Hull, who also at the time
founded the company, 3D Systems.
 Digital Light Processing (DLP)
DLP or Digital Light Processing refers to a method of printing that makes use of
light and photosensitive polymers. While it is very similar to stereolithography,
the key difference is the light-source. DLP utilises traditional light-sources like
arc lamps. In most forms of DLP, each layer of the desired structure is projected
onto a vat of liquid resin that is then solidified layer by layer as the build plate
moves up or down. As the process doeseach layer successively, it is quicker than
mostforms of3D printing. The Envision Tec Ultra, MiiCraft High Resolution 3D
printer, and Lunavast XG2 are examples of DLP printers.
 MaterialJetting
In this process, material is applied in droplets through a small diameter nozzle,
similar to the way a common inkjet paper printer works, but it is applied layer-
by-layer to a build platform making a 3D object and then hardened by UV light.
 Selective LaserSintering (SLS)
SLS uses a high power laser to fuse small particles of plastic, ceramic or glass
powders into a mass that has the desired three dimensional shape. The laser
selectively fuses the powdered material by scanning the cross-sections (orlayers)
generated by the 3D modeling program on the surface of a powder bed. After
each cross-sectionis scanned, the powder bed is lowered by one layer thickness.
Then a new layer of material is applied on top and the process is repeated until
the object is completed.

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 DirectMetal LaserSintering (DMLS)
DMLS is basically the same as SLS, but uses metal instead of plastic, ceramic or
glass. All untouched powderremains as it is and becomes a supportstructure for
the object. Therefore there is no need for any support structure which is an
advantage over SLS and SLA. All unused powder can be used for the next print.
SLS was developed and patented by Dr. Carl Deckard at the University of Texas
in the mid-1980s, under sponsorship of DARPA.
DIFFERENCES BETWEEN 3D PRINTING& CAD
 CAD or Computer Aided Designing.
It covers 2D Drawings, 3D Models of Parts, Assemblies and even gigantic
projects. Fit and Function Testing is possible once we have the CAD Data of
whatever we’re designing. A CAD model can also be considered as a virtual
prototype.
 3D Printing
3D Printing is a process of making objects by adding up material (contrary to
subtraction ofmaterial as in CNC Machining). We build only as much as we need.
Rest of the raw material is unaffected.
ADVANTAGES AND DISADVANTAGES OF 3D PRINTING
Advantages:
 Customization – A major advantage in 3d printing. With just a raw
material, a blueprint and a 3d printer, one can print any design no matter
how complex it might be.
 Constant Prototyping and Increased Productivity – It enables quick
production with a high number of prototypes or a small-scale version of
the real object in less time than using conventional methods. This helps

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designers to improve their prototypes, forany design flaws that may affect
the quality of the product.
 Affordability – The initial cost for setting up a 3d printing facility is
definitely high; however, it is much cheaper compared to labor costs and
manufacturing costs while using the conventional way. Adding to it, is the
fact that the costofproducing or manufacturing products using 3d printing
technology is equal for small-scale and mass manufacturing.
 Storage – Traditionalmanufacturing produces additionalproducts thatyou
probably know you will eventually need thus storage problems arise.
However, 3d printing technology, products can be “printed” when needed
thus excess products are eliminated and no storage costis required.
 Employment Opportunities – The widespread use of 3d printing
technology will definitely increase the demand for engineers who are
needed to design and build these printers. Technicians who are skilled at
troubleshooting and maintenance and Designers to design blueprints for
products and more jobs will be created.
 Health Care – With the advancement of technology, a customizable
human bodyparts and organs can now be manufactured this technology is
termed as Bioprinting. Although right now this is still experimental, the
potential is huge. This breakthrough will not only address the shortage of
organ donors, but also organ rejection since the organs that are built will
consist of the patient’s unique characters and DNA.
Disadvantage:
 Decrease in Manufacturing Jobs – The decrease in manufacturing jobs
will greatly affect the economy of countries that rely on a large number of
low skill jobs.

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 Limited Size – The size of objects created with 3d printers is currently
limited however, in the near future; large items such as architectural
structures can be created using 3d printing.
 Limited Raw Materials – Traditional manufacturing of products has an
enormous range ofraw materials that canbe used. Presently 3d printers can
work up to approximately 100 different raw materials and creating
products that uses more raw materials are still under development.
 Violation of Copyrights – The biggest disadvantage of 3d printing is
Counterfeiting. Anyone who gets a hold of a blueprint will be able to
counterfeit products easily. It will become more common and tracing the
source of the counterfeited items will be nearly impossible. Many
copyright holders will have a hard time protecting their rights and
businesses producing unique products will suffer.
 Production of Dangerous Items – With 3d printers, plastic knives, guns
and any other hazardous objects can be created. It makes easier for
terrorists and criminals bring a weapon without being detected.
APPLICATIONS OF 3D PRINTING
 Education
3D printing in education allows students to print and test their designs. They can
also see what changes or improvements need to be done. This way they can learn
through trial and error since it only takes a little time and money to adjust the
design. This can help enhance their learning.
 Dental
3D printing can help create molds that are more durable and resistant to high
pressure and temperatures. Furthermore, with a very high resolution and a small
layer thickness, it is possible to create perfect teeth.

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 Engineering
Engineers can use 3D printing to design or make prototypes. Moreover, the
materials for 3D printing are stronger and more resistant so you can print parts
that are fully functionable.
 Architecture
3D printing allows architects bring their vision and design to life. It also allows
them to combine form and function and create something completely new and
unique. Therefore, with 3D printing, it is possible to quickly create a tangible
model. 3D printing also gives you the freedom in designing an object.
 Low-volume manufacturing
Though 3D printers can be slow moving, they're adept at fulfilling low-volume
production needs. Much like with prototyping, if an entrepreneur is ready to
launch a new productand isn't certain of the demand, he or she can print a small
amount to test the waters. Low-volume productionis also commonwhen it comes
to medical devices, for example, as manufacturers create, test and redesign their
products foroptimization. While low-volume manufacturing suits the capabilities
of3D printing, advances in technology make 3D printing a viable optionofhigher
volume production as well. Small businesses should consider the potential value
of 3D printing in the mass customization of goods.
 Mechanicalparts
Another beneficial use for 3D printers is the creation of mechanical parts, either
for sale in large industries or for personal repairs. Many products of 3D printing
aren't sold directly to consumers but are created by companies (or third-party
contractors)as components in a larger project. One example is GE Aviation's 3D

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printed fuel nozzle. The company recently produced its 30,000th nozzle after
starting productionin 2015.
Small machine shops or individuals looking to make home repairs can also
employ the same techniques for their projects. 3D printing has made it far easier
to reproduce parts for machines that might no longer be in production or that
would take too long to arrive.
 Biomedical
One particularly exciting aspect of 3D printing is the ability to print biomedical
devices tailored specifically to individuals. For example, some companies are
developing 3D printed, custom prosthetics for amputees; these prosthetics are
designed to be far more comfortable for the user.
 Design
When engineers design a product, they must keep in mind the limitations of the
production process. 3D printers can create parts previously considered
unachievable using traditional manufacturing techniques. This opens an entirely
new world in the design phase, which can lead to better, more efficient products
and componentparts. Many of these 3D printed creations add value to important
products, while others are downright unusual.
EXAMPLES OF 3D PRINTING BENEFITED BUSINESS
 Ford
Ford is also applying 3D printing to make engine covers for the 2015 Ford
Mustang. The technology that they use helps to save huge amounts of waste, time
and money to create these particular pieces. The company, given their positive
results in this particular project, will test 3D printing for other, larger car parts for
cost effective customization. This same approach has been applied by other car

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manufacturers like McLaren. The following video shows the 3D printing of car
pieces.
 VolkswagenAutoeuropa
3D printing can be an asset on different levels, and not only for your products.
We saw on our recent blogpost that 3D printing tools could considerably reduce
your tooling investment. For example, do you know that Volkswagen
Autoeuropa, the car manufacturer, is using 3D printing to manufacture some of
its tools? The company actually estimates that thanks to 3D printing they saved
250,000€ in 2017. No matter what your sector is, reducing your tooling costs
could really be a huge asset for your company.
Using additive manufacturing to get custom made tools is reducing costs, but is
also a convenient method that could help you to create a successfulbusiness. This
way, these tools are totally adapted to their activity, and they are quite less
expensive than with another traditional manufacturing technique.
 Adidas
We already saw on our blog that additive manufacturing is an amazing
manufacturing method to create custom-madeshoes. Adidas created different 3D
printing projects, and has been working on sneakers made with plastic found in
the ocean. It is actually showing how plastic can be recycled and used by 3D
printing businesses. Recycling plastic parts could be more and more important in
the 3D printing industry in the upcoming years.
THE IMPACT OF 3D PRINTING ON THE SUPPLY CHAIN
The future of 3D printing lies in the business opportunities that lie in adoptionof
the technology. One area businesses have seen immense value is 3D printing’s
impact on the supply chain. With top 3D printing companies rapidly making the

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technology more accessible to a wide range of industries, more and more
companies have embraced 3D printing’s streamlined supply chain.
The benefits of this optimized supply chain are increasingly evident.
Transitioning to on-demand manufacturing leads to cost savings by eliminating
or significantly reducing inventory requirements. The benefits of digital files also
provide the ability to quickly producenew iterations at little to no additional cost.
With a single sourcefora variety ofparts, businesses that use 3D printing contract
manufacturers deal with less risk, more control and added agility in relation to
their productlifecycle. Localfacilities can 3D print designs on-demand from files
sent across the globe, or they can print securely from a nearby supplier. The
infographic below offers an illustrated look at the differences between a
traditional supply chain and one that utilizes 3D printing.
3D PRINTING IMPACT ON BUSINESS MODELS
3D printing enables a shift from designing for ideal manufacturing to
manufacturing the ideal design. Historically, products were designed to be made
with high efficiency and low cost, hence, every customer received the same thing
as every other customer did. 3D printing changes the classical ROI equation —
now very short runs, all the way down to quantities of one piece per order, are
practical and cost-effective.
3D printing can have a beneficial impact on finances by cutting production,
inventory and manufacturing costs. Enterprise-class 3D printers are available for
a wide and growing range of providers, who are offering improved performance
at lower cost. Forexample, Admatec, Desktop Metal, Formlabs and Markforged
have introduced 3D printers that work with metals or ceramics in an office
environment.

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3D printing can enable new value propositions that transform existing and
facilitate new customer relationships. Most organizations, in an effort to assure
their value proposition and therefore their customers’ expectations are met, have
standardized their offerings to a fault. Such risk avoidance leads to lowest
common denominator products, where, to paraphrase Henry Ford, every
customer gets the same thing as long as it is black. 3D printing transforms
customer relationships from “product push” by marketing to new on-demand
“product pull” models. Customer relationships become more agile with 3D
printing as they call for on-demand solutions tailored to their exact specifications.
3D printing can not only deliver immediate benefits to existing manufacturing
business models, but also be a disruptive technology that enables radically new
business models suchas mass customization. 3D printing can enable low-volume,
on-demand, customized productionnear the point ofuse. 3D printing also creates
a competitive threat if the competition sees additive manufacturing’s potential
and acts on it, and your clients switch to their 3D printed offerings.
Prepare for business model change from 3D printing and collaborate with your
management and peers to phase in changes by analysing its impacts on your
business model.
FINDINGS
• Aid World Hunger
• Custom,Affordable prosthetics
• An Industrial Revolution
• Complete Customization
• Fun,New Food
• Safer SpaceTravel
• Less Waste
• More Power To The People
• Small Business Empowerment
• CoolerArt

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