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Abdul Rafay Hassaan Khan Ammar Majid Waqas Anjum

 Additive manufacturing or 3D printing is a process of making a three-dimensional solid object of virtually any shape from a digital model. 3D printing is achieved using an additive process, where successive layers of material are laid down in different shapes. It is distinct from traditional machining which rely on material removal. The technology is used for both prototyping and distributed manufacturing in jewelry, footwear, industrial design, architecture, engineering and construction (AEC).

 Additive manufacturing takes virtual blueprints from computer aided design (CAD) or animation modeling software and "slices" them into digital cross-sections for the machine to successively use as a guideline for printing. A standard data interface between CAD software and the machines is the STL file format. An STL file approximates the shape of a part or assembly using triangular facets. PLY is a scanner generated input file format, and VRML (or WRL) files are often used as input for 3D printing technologies that are able to print in full color.

 To perform a print 1. the machine reads the design from an .stl file and 2. lays down successive layers of liquid, powder, paper or sheet material to build the model from a series of cross sections.

 After each layer, the part is heated to a desired temperature for a definite time. The heating time obviously depends upon the nature of material, geometry, finish et6c. When heated the polymer layer fuses into the previous layer making a whole solid shape. Layers of different colors and materials are also used when desired. It is generally most time consuming process of the process.

 Printer resolution describes layer thickness and X-Y resolution in dpi (dots per inch), or micrometers. Typical layer thickness is around 100 micrometers (0.1 mm), although some machines such as the Objet Connex series and 3D Systems' ProJet series can print layers as thin as 16 micrometers The particles (3D dots) are around 50 to 100 micrometers (0.050.1 mm) in diameter.

 Construction of a model with contemporary methods can take anywhere from several hours to several days. Depending upon the size and complexity. Additive systems can typically reduce this time to a few hours, although it varies widely depending on the type of machine used and the size and number of models being produced simultaneously.

 Though the printer-produced resolution is sufficient for many applications, printing a slightly over sized version of the desired object in standard resolution. Traditional machining processes are generally used to finish.

 Colors: Different color material are also used where desired. Different materials: Printers also use different materials for the process. Supports: Some printers utilize supports for complex geometries. Supports are generally removable or dissolvable.

 A number of additive processes are now available. They differ in the way layers are deposited to create parts and in the materials that can be used. Some methods melt or soften material to produce the layers, e.g. selective laser sintering (SLS) and fused deposition modeling (FDM), while others cure liquid materials using different sophisticated technologies, e.g. stereolithography (SLA). With laminated object manufacturing (LOM), thin layers are cut to shape and joined together (e.g. paper, polymer, metal). The main considerations in choosing a machine are generally speed, cost of the 3D printer, cost of the printed prototype, and cost and choice of materials and color capabilities.

Type Extrusion Wire

Technologies Fused deposition modeling (FDM) Electron Beam Freeform Fabrication (EBF) Direct metal laser sintering (DMLS)

Materials Thermoplastics (e.g. PLA, ABS), HDPE, eutectic metals, edible materials Almost any metal alloy Almost any metal alloy

Electron beam melting (EBM)

Granular Selective heat sintering (SHS) Selective laser sintering (SLS) Powder bed and inkjet head 3d printing, Plaster-based 3D printing (PP) Laminated Light polymerised Digital Light Processing (DLP) Laminated object manufacturing (LOM) Stereolithography (SLA)

Titanium alloys
Thermoplastic powder Thermoplastics, metal powders, ceramic powders Plaster Paper, metal foil, plastic film photopolymer Photopolymer

 Developed by S. Scott Crump in the late 1980s,commercialized in 1990 by Stratasys. Uses a plastic filament or metal wire that is wound on a coil and unreeled to supply material. Extrusion nozzle heats to melt the material,can be moved in horizontal and vertical directions by a numerically controlled mechanism Stepper or servo motors are typically employed . Various polymers are used, including acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polylactic acid (PLA), high density polyethylene(HDPE), PC/ABS, and polyphenylsulfone (PPSU). Polymer is in the form of a filament; fabricated from virgin resins. FDM has some restrictions on the shapes to be fabricated. For example, FDM usually cannot produce stalactite-like structures, since they would be unsupported during the build.

 Selective fusing of materials in a granular bed.Fuses parts of the layer, and moves the working area downwards, is repeated several times. Uses the un fused media to support overhangs and thin walls in the part. Uses laser to sinter the medium in solid. Eg. selective laser sintering (SLS), with both metals and polymers (e.g. PA, PA-GF, Rigid GF, PEEK, PS, Alumide, Carbonmide, elastomers), and direct metal laser sintering (DMLS).

 Uses paper as a build material During 1990s, companies could cut cross sections out of special adhesive coated paper by a carbon dioxide laser, and laminate them together. In 2005 by Mcor tech: process used a Tungsten carbide blade to cut the shape, and selective deposition of adhesive and pressure to bond the prototype.

 Was patented in 1987 by Chuck Hull. Photopolymerization is primarily used in stereolithography (STL) to produce a solid part from a liquid. In digital light processing (DLP), a vat of liquid polymer is exposed to light from a DLP projector under safelight conditions. The exposed liquid polymer hardens. The build plate then moves down and process is repeated. The remaining liquid is then removed leaving a solidified part.

 RepRap: Which is capable of replicating itself by printing many of its own (plastic) parts to create more machines. The least expensive assembled machine available is the Solidoodle 2, while the RepRapPro's Huxley DIY kit is reputedly one of the more reliable of the lower-priced machines

 Rapid prototyping: Generally larger machines; uses proprietary powdered metals, casting media (e.g. sand), plastics etc Rapid manufacturing: Is a new method of manufacturing and many of its processes remain unproven. 3D printing is now entering the field of rapid manufacturing and was identified as a "next level" technology by many experts in a 2009 report. Mass production: Used to mass produce, print in colors,different polymers, or make multiple prints simultaneously. This increases their overall print speed with less capital cost since they share a single controller. Domestic and hobbyist uses: Has mainly captivated hobbyists and enthusiasts and has not quite gained recognition for practical household applications.

Shorten design cycles Less waste Cheaper running cost (high initial cost though) Superior products on the market ahead of the competition Hollow parts Improve accuracy Eliminate costly mistakes

 Current 3D printing materials for investment casting tend to yield sporadically rough surfaces. Sometimes encourages informal design methods which may cause more problems to fix. It may not be suitable for large sized applications. 3-D printers are still expensive.