3D printing is an additive manufacturing process that creates physical objects from digital files. It works by building up a product layer by layer from a 3D model. There are different 3D printing technologies that use various materials like plastics, metals, and alloys. 3D scanning allows the digital capture of physical objects to create 3D models. Key components of 3D printers include the print bed, extruder, stepper motors, and frame. 3D printing has evolved significantly since its invention in the 1980s and is now used across many industries.

1. 3D Printing
INTRODUCTION TO 3D PRINTING:
3D Printing is an additive manufacturing process that creates a physical object
from a digital design. There are different 3D printing technologies and materials you
can print with, but all are based on the same principle: a digital model is turned into a
solid three-dimensional physical object by adding material layer by layer.
OR
The action or process of making a physical object from a three-dimensional digital
model, typically by laying down many thin layers of a material in succession.
"if you use 3D printing for prototypes you will simply be able to go to market faster"
HOW IT WORKS-
Every 3D print starts as a digital 3D design file – like a blueprint – for a physical
object. Trying to print without a design file is like trying to print a document on a sheet
of paper without a text file. This design file is sliced into thin layers which is then sent
to the 3D Printer.
From here on the printing process varies by technology, starting from desktop printers
that melt a plastic material and lay it down onto a print platform to large industrial
machines that use a laser to selectively melt metal powder at high temperatures. The
printing can take hours to complete depending on the size, and the printed objects are
often post-processed to reach the desired finish.Available materials also vary by
printer type, ranging from plastics to rubber, sandstone, metals and alloys - with more
and more materials appearing on the market every year.
3D SCANNING:
3D Scanning technologies allow for the creation of of 3-dimensional objects. By using
3D scanning you will be able to capture a digital copy of a physical real world object.
To exemplify the extent to which 3D scanning will have impact, imagine for example
the reconstruction of a severely damaged human skull, that was scanned and
replicated in titanium.
Now let’s get practical. For 3D printing, there are roughly two relevant techniques of
3D scanning:
1.Photogrammetry-
Photogrammetry is the easiest way to get started in 3D scanning. The method is
based on taking 2D pictures around an object, from different angles, and stitching
them together into a single 3-Dimensional image. The last part being handled by
software. It only requires a camera to do so and that means that you can go ahead
and do it right now, even with your smartphone. Next step is to stitch your photos
together to create a 3 dimensional mesh of the object you captured. 123D Catch,
Trimensional, or Trnio are all great apps for this. The software will match all
overlapping points of the images and create a 3D model.

2. 3D Printing
2.Light-based scanning-
*Structured light scanners send patterns of light onto the object to capture. Based
on the deformations of the pattern it determines the model form and creates a 3D
mesh, or digital replica.
*Laser scanning uses a slightly different method. It measures the angle of the
reflected lasers which it can translate into coordinates of an object and therefore into
a 3D mesh.
Most of the current hand-held scanners use the laser scanning technology. Some of
them likeStructure.io or iSense are simply a laser with a sensor that you can mount
on your smartphone or iPad. While others use a small spinning platform, to place an
object on and scan while it is the object that turns.

3. 3D Printing
3D Scanning Advantages:
1. Quickly capture all of the physical measurements of any physical object
2. Save time in design work
3. Ensure parts will fit together on the first try
4. Capture engineering optimizations inherent in manufactured parts
5. Utilize modern manufacturing on parts that were originally manufactured before
CAD
6. Compare “as-designed” model to “as-built” condition of manufactured parts
3D PRINTING:

4. 3D Printing
JOURNEY OF 3D PRINTING TECHNIQUE:
3D Printing seems to be a new technology, but in actual started arising from 1980.
This took a long way to develop and come in to the form of today. Here are some
points about the history of this technique:-
The first 3D printing attempts are granted to Dr Kodama for his development of a
rapid prototyping technique in 1980. He was the first to describe a layer by layer
approach for manufacturing, creating an ancestor for SLA: a photosensitive resin was
polymerised by an UV light.. Four years later, a French team of engineers was
interested by the stereolithography but abandoned due to a lack of business
perspective.
In the same time, Charles Hull was also interested in the technology and deposited a
first patent for stereolithography (SLA) in 1986. He founded the 3D Systems
Corporation and a year later, released the SLA-1.
In 1988, at the University of Texas, Carl Deckard brought a patent for the SLS
technology, another 3D printing technique in which powder grains are fused together
locally by a laser.
In 1992, the Fused Deposition Modeling patent was issued to Stratasys, who that
developed many 3D printers for both professional and individuals.
From 1993 to 1999, the main actors of the 3D printing sector emerged with various
techniques:
1. ZCorp and binder jetting: Based on MIT’s inkjet printing technology, they created the
Z402, which produced models using starch- and plaster‐based powder materials and
a water‐based liquid binder
2. Arcam MCP technology and Selective Laser Melting.
At the same time, CAD tools for 3D printing became more and more available and
developed, with for example the creation of Sanders Prototype (now known as
Solidscape), one of the first actors to develop specific tools for additive
manufacturing.
Now the 3D painting is used in almost every manufacturing industries because of
reduction in cost and complexity.

5. 3D Printing
Here is the recap of revolution in 3D technique and it’s uses:-
1980: first patent by Japanese Dr Kodama Rapid prototyping
1984: Stereolithography by French then abandoned
1986: Stereolithography taken up by Charles Hull
1987: First SLA-1 machine
1988: First SLS machine by DTM Inc. then buy by 3D system
1990: First EOS Stereos system
1992: FDM patent to Stratasys
1993: Solidscape was founded
1995: Z Corporation obtained an exclusive license from the MIT
1999: Engineered organs bring new advances to medicine
2000: a 3D printed working kidney is created
2000: MCP Technologies (an established vacuum casting OEM) introduced
the SLM technology
2005: Z Corp. launched Spectrum Z510. It was the first high-definition color 3D
Printer on the market.
2006: An open source project is initiated (Reprap)
2008: The first 3D printed prosthetic leg
2009: FDM patents in the public domain
2009: Sculpteo is created
2010: Urbee is the first 3D printed prototype car presented
2011: Cornell University began to build 3D food printer.
2012: The first prosthetic jaw is printed and implanted
2013: “3D printing” in Obama’s State of the Union speech
2015: Carbon 3D issues their revolutionary ultra-fast CLIP 3D printing machine
2016: Daniel Kelly’s lab announces being able to 3D print bone

6. 3D Printing
COMPONENTS OF A 3D PRINTER:
1.Print Bed
The print bed is the surface that your objects are printed on to. Typically it will consist
of a sheet of glass, a heating element, and some kind of surface on top to help the
plastic stick.
 Heated/Non-Heated
Most print beds are heated in order to prevent the object from warping while it is being
printed. Due to thermal contraction, the plastic will shrink slightly as it cools. This
causes the object to warp upwards around the edges and peel off the bed. Heated
beds keep the bottom of the object warm, in order to prevent this
Some printers do not have heated beds. This limits them to printing a narrow range of
materials including mainly PLA (the material that is least prone to warping) and
sometimes PET.
2.Bed Surfaces
The bed surface helps the plastic stick to the bed during printing but also allows it to
be removed easily when printing is done. There are many different kinds of bed
surfaces. Most printers will come with some kind of all purpose surface, like BuildTak

7. 3D Printing
or PEI film. However, for best results you will want to use different surfaces
depending on the material you are printing.
3.Filament
This is the plastic that's consumed by the printer. It comes on a spool. Printers use
two different sizes of filament, 1.75 mm and 3 mm. There are a variety of different
materials.
4.Extruder
The extruder is the core of the printer. It is where the plastic gets drawn in, melted,
and pushed out. It is essentially a fancy hot glue gun. It is small, but it is where most
of the printer’s technology is located. The extruder consists of two parts; the hot end
and the cold end. The cold end has a motor that draws the filament in and pushes it
through. The hot end is where the filament gets melted and squirted out.
 Direct Drive vs Bowden Extruders
On direct drive printers, the hot end and cold end are connected together, one on top
of the other. The filament goes straight down through the cold end and into the hot
end.
With a Bowden setup, the hot end and cold end are separated. The cold end will be
stationary and bolted somewhere onto the printer’s frame. The filament is pushed
through a long tube (called a Bowden tube) to the hot end. This means that the printer
has less weight to move around.
5. Hobbed Gear

8. 3D Printing
This gear bites the filament and pushes it down through the hot end
6. Idler gear
The idler is a spring loaded wheel that pushes the filament up against the hobbed
gear. Most printers have a way to adjust the tension on the idler, so that it neither
squeezes the filament too hard or too little.
7.Hot end - All Metal vs PEEK/PTFE
By not using any plastic insulators in their construction, all metal hot ends are able to
reach much higher temperatures and print a wider range of materials. However, they
require active cooling.
8.Hot end - Heat Sink / Hot End Fan
This ensures that heat does not travel up the plastic and melt it prematurely before it
reaches the nozzle. This phenomenon is called heat creep and it causes jams,
especially with PLA. This fan should be running whenever the hot end is warm.
9.Heater Cartridge
The heater cartridge is pretty self explanatory. It heats the plastic. It is simply a high
power resistor. Almost all modern printers use cartridge heaters, but many older
printers used coils of nichrome wire (like the kind in a toaster). If you are replacing
your heater cartidge, of even your entire hotend, make sure you know if your system
is running 12v or 24v.
10.Thermistor/Thermocouple/RTD

9. 3D Printing
These are all various types of sensors for determining the temperature of the hot end.
They are essentially electronic thermometers. Thermistors are the most common type
of sensor, but some printers will use thermocouples for extremely high temperature
printing.
11.Nozzle
The nozzle is simply a piece with a small hole for the melted filament to come out of.
Nozzles are interchangeable, and come in various sizes; 0.4 mm is normal, while you
might use a smaller nozzle for finer detail or a larger nozzle to print faster. Nozzles
can also sometimes get clogged. This is one of the most common issues with 3D
printers. See this article for advice on unclogging your nozzle .
12.Layer cooling fan
This fan cools off the plastic immediately after it is deposited by the nozzle. It helps
the object hold its shape. The slicer will turn this fan on and off under different
circumstances, depending on what material you are printing. It is not to be confused
with the heat sink fan, which cools the hot end itself and not the printed object.
14. Motion Control - X, Y, Z Axis:

10. 3D Printing
 Delta VS Cartesian
*Cartesian printers move one or two motors along each of the X, Y, and Z axes and
the name was derived from the Cartesian coordinates system. They typically have a
rectangular build area and the printers themselves tend to have a cube-like shape.
The Lulzbot Mini is a fine example of these types of printers.
*Delta printers have three arms that come together in the center to suspend the
extruder above the build area. Deltas also use a Cartesian coordinates system to
move around in, but instead of moving one motor per axis at a time, all three arms
move at different rates or times to precisely move the nozzle with triangulation. The
SeeMeCNC Rostock MAX V2 is a prime example of a delta printer.
15.Threaded Rods / Leadscrews
These are usually used on the printer’s Z axis. They rotate, thus forcing nuts to move
up and down. Inexpensive printers will use simple threaded steel rods, which are
essentially extra long bolts. Higher quality printers have smooth chrome plated
leadscrews designed to minimize backlash.
16.Belts
Belts move things. The X and Y motors have sprockets that drive the belts. Most
printers also have some way of adjusting the tension on the belts.
17.Stepper Motors

11. 3D Printing
Unlike regular DC motors, which rotate continuously when given power, stepper
motors rotate in increments. This gives them precise control over their position. Most
printers use NEMA 17 type motors with 200 increments (steps) per revolution.
18.Frame
The frame holds everything together. Early printers had frames made out of lasercut
plywood. Printers now have frames made of sheet metal, aluminium beams, or
plastic. Many parts of the frame are often 3D printed themselves. The more rigid the
frame, the more precise the printer’s movement will be.
19.Enclosure
Enclosures for 3D printing are used for safety. There are moving parts and heating
elements that users will want to protect themselves from. If you printer does not offer
an enclosure it is easy to construct your own. Something as simple as a cardboard
box could suffice.
20.Electrical components:
 Power Supply
This takes the 120V AC electricity from the wall and converts it to low voltage DC
power for your printer to use
ATX Power Supplies- These are the same power supplies used in desktop
computers. They have been repurposed for use in many printers. They are very beefy
and efficient, and have separate lines that provide power at a variety of voltage (12V,
5V, 3.3V).
Voltage - some machines run 12 volt systems, while others run 24 volt systems. This
becomes critical if you are going to replace components - especially your heater
cartridge or hotend. Make sure you order the appropriate parts.
 Motherboard

12. 3D Printing
The motherboard is the brain of the printer. It takes the commands given to it by your
computer (in the form of G-Code ) and orchestrates their execution. The motherboard
contains a microcontroller (essentially a tiny, self contained computer) and all the
circuitry needed for running the motors, reading the sensors, and talking to your
computer.
 Stepper Drivers
These chips are responsible for running the stepper motors. They fire the coils of the
motor in sequence, causing it to move in increments. Many motherboards have the
stepper drivers built in, but some also have them in modules that can be unplugged.
By balancing the power fed to each coil, the driver is also able to divide steps up into
further increments. This is called microstepping, and allows more precise control over
the motor than is normally possible. The stepper driver also controls how much
electrical current is fed to the motor. More power makes the motor stronger, but also
makes it run hotter.
 User interface
Some printers have an LCD screen so they can be controlled directly without hooking
them up to a computer. These can be basic black and white displays like the VIKI 2 or
advanced wifi enabled touchscreens like the MatterControl Touch.
 SD Card Slot

13. 3D Printing
Some printers also have an SD card slot from which they can load G-Code files. This
allows them to run independently without a computer.
21. End Stops (one for each axis)
The endstops are how the printer knows where it is. They are little switches that get
pushed whenever an axis moves to the end. This is how the printer finds it’s starting
point before printing. Most printers use mechanical switches, but some are known to
use optical sensors.
22. Bed Leveling
Many printers have some kind of a system for automatically making sure that the bed
is level with the nozzle. Some do not, though, and must be calibrated by hand.
MatterControl also has the ability to account for unlevelness in software.
What Materials are Used to Make the Printer?
An example of how a 3-D printer, The MakerGear Mosaic, is put together is given
below:
The Frame has nine sections that are laser cut from 0.200" plywood and assembled
by securing them with the built-in captive-nut mortise-and-tenon joints.
The Y-axis system is probably the largest sub-assembly including the Y-axis motor
mount, which is normally preassembled and in this step, it is decorated with various
components such as the stepper motor, the linear rail and the timing belt.
The Y-axis assembly is straightforward including fixing the idler pulley shaft, the
bolting motor, linear rail and rail stops to the already assembled frame. The X-axis
timing belt is then installed and adjusted.
The Z-axis assembly includes installing two hardened precision ground steel shafts
that guide the build platform along its vertical travel path, the Teflon-coated lead
screw driving it and the stepper motor turning the lead screw. At this stage, the Z-axis
limit switch is also installed.
The extruder assembly includes the preassembled motor, filament drive or hot end
groups and the cooling fan. The heater, fan and temperature sensor are also
connected at this stage.
The build assembly includes installing and adjusting the leveling platform, mounting
the heating element and the build surface and making the related electrical
connections.
The electronics assembly includes wiring and installing the electronics controlling the
printer. Firstly, the Ardiuno and the RAMP shield attached to it are mounted on the
printer frame. Next, connections from the extruder wiring harness, the build platform

14. 3D Printing
wiring harness and other components are clipped to the printed circuit board. Lastly
the power supplies are connected and the printer is formally assembled.
The options and preferences of operating the printer are varied and depend on the
computer being used, the operating system on the computer as well as CAD, CAM
and printer control programs chosen.
MATERIALS USED IN 3D PRINTING:
In terms of raw materials that are put into the printing system to create the 3-D
objects, there seem to be relatively few limitations on what can be used.
Currently, plastics are the most widely used materials in additive manufacturing, and
the important ones are listed below:
1. ABS - acrylonitile butadiene styrene or 'lego' plastic – a very common choice for 3D
printing
2.PLA - polylactic acid – Is available in soft and hard grades, is becoming very
popular and may overtake ABS in the near future
3.PVA - polyvinyl alcohol – This is used as a dissolvable support material or for
special applications.
4.PC – polycarbonate – Polycarbonate requires high-temperature nozzle design and
is in the proof-of-concept stage.
5.SOFT PLA - polylactic acid – Is rubbery and flexible, available in limited colors and
sources. As 3D printing spreads, may get easy to find.
Applications of 3D Printing:

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PolyJet and FDM Technology is in use by these industries to design faster and
more innovative.
1.Aerospace Industry
2.Architecture Industry
3.Automotive Industry
4.Commercial Products

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5.Consumer Goods Industry
6.Consumer Electronics
7.Defense Industry

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8.Dental Industry
9.Education Industry
10.Medical Industry

18. 3D Printing
11.Mold Industry
Other Applications of 3D printing:

19. 3D Printing
1. Manufacturing applications-
Additive manufacturing in combination with cloud computing technologies allows
decentralized and geographically independent distributed production. Cloud-based
additive manufacturing refers to a service-oriented networked manufacturing model in
which service consumers are able to build parts through Infrastructure-as-a-Service
(IaaS), Platform-as-a-Service (PaaS), Hardware-as-a-Service (HaaS), and Software-
as-a-Service (SaaS). Distributed manufacturing as such is carried out by some
enterprises; there is also a services like 3D Hubs that put people needing 3D printing
in contact with owners of printers. Some companies offer on-line 3D printing services
to both commercial and private customers, working from 3D designs uploaded to the
company website. 3D-printed designs are either shipped to the customer or picked up
from the service provider.
2.Mass customization-
Miniature face models (from FaceGen) produced using Ceramic Based material on a
Full Colour 3D Inkjet Printer. Companies have created services where consumers can
customize objects using simplified web based customisation software, and order the
resulting items as 3D printed unique objects. This now allows consumers to create
custom cases for their mobile phones. Nokia has released the 3D designs for its case
so that owners can customize their own case and have it 3D printed.
3.Rapid prototyping-
Industrial 3D printers have existed since the early 1980s and have been used
extensively for rapid prototyping and research purposes. These are generally larger
machines that use proprietary powdered metals, casting media (e.g. sand), plastics,
paper or cartridges, and are used for rapid prototyping by universities and commercial
companies.
ADVANTAGES OF 3D PRINTING:

20. 3D Printing
1.Speed-
One of the main advantages of additive manufacture is the speed at which parts can
be produced compared to traditional manufacturing methods. Complex designs can
be uploaded from a CAD model and printed in a few hours. The advantage of this is
the rapid verification and development of design ideas.
Where in the past it may have taken days or even weeks to receive a prototype,
additive manufacturing places a model in the hands of the designer within a few
hours. While the more industrial additive manufacturing machines take longer to print
and post process a part, the ability to produce functional end parts at low to mid
volumes offers a huge time saving advantage when compared to traditional
manufacturing techniques (often the lead time on a injection molding die alone can be
weeks).
 Single step manufacture-
One of the biggest concerns for a designer is how to manufacture a part as efficiently
as possible. Most parts require a large number of manufacturing steps to produce and
the order the steps occur in affects the quality and manufacturability of the design.
Consider a custom steel bracket that is made via traditional manufacturing methods.
Like additive manufacturing the process begins with a CAD model. Once the design is
finalized fabrication begins with the steel being cut to length. The cut lengths are then
clamped into position and welded one at a time to form the bracket. Sometimes a jig
will need to be made up to ensure all components are correctly aligned. The welds
are then ground to give a good surface finish. Next holes are drilled so the bracket
can be mounted to the wall. Finally the bracket is sand blasted, primed and painted to
improve its appearance.
Additive manufacturing machines complete a build in one step with no interaction
required during the build phase. For additive manufacturing as soon as the CAD
design is finalized it can be uploaded to the printer and printed in one step in a couple
of hours.
The ability to produce a part in one step greatly reduces the dependence on different
manufacturing streams (machining, welding, painting) and gives the designer greater
control over the final product.
2.Cost-
The cost of manufacture can be broken down into 3 categories; machine operation
costs, material cost and labor costs.
(A) Machine operation costs: Most desktop 3D printers use the same amount of
power as a laptop computer. More industrial additive manufacturing technologies
consume a high amount of energy to produce a single part however the ability to
produce complex geometries in a single step results in higher efficiency and
turnaround. Machine operation costs are typically the lowest contributor to the overall
cost of manufacture.
(B) Material costs: The material cost for additive manufacturing varies significantly by
technology. Desktop FDM printers use filament coils that cost around $25 per kg
while SLA printing requires resin that retails around $150 per litre. The range of
materials available for additive manufacturing make quantifying a comparison with

21. 3D Printing
traditional manufacturing difficult. Nylon powder used in SLS costs around $70 per kg
while comparable nylon pellets used in injection molding can be purchased for as little
as $2 - $5 per kg. Material costs are the biggest contributor to the cost of a part made
via additive manufacturing.
(C) Labor costs: One of the main advantages of 3D printing is the the cost of labor.
Post processing aside, the majority of 3D printers only require an operator to press a
button. The machine then follows a completely automated process to produce the
part. Compared to traditional manufacturing where highly skilled machinists and
operators are typically required, the labor costs for a 3D printer are almost zero.
Additive manufacturing at low volumes is very cost competitive compared to
traditional manufacturing. For the production of prototypes that verify form and fit, it is
significantly cheaper than other alternative manufacturing methods (injection molding)
and is often competitive for manufacturing one off functional parts. Traditional
manufacturing techniques become more cost effective as volumes begin to increase
and the high setup costs are justified by the large volumes of productions.
3.Risk mitigation-
An order of a prototype that is faulty costs time and money. Even small changes in a
mold or fabrication can have a large impact on cost. Being able to verify a design by
printing a production-ready prototype before investing in expensive manufacturing
equipment (molds or tooling and jigs) takes the risk out of the prototyping process.
This builds confidence before making the large investments required at the mass
production level.
4.Complexity and design freedom-
The restrictions imposed by traditional manufacturing on what can be made are
generally not relevant for additive manufacturing. Because components are
constructed one layer at a time design requirements such as draft angles, undercuts
and tool access do not apply when designing parts to be 3D printed. While there are
some restrictions on the minimum size features that can be accurately printed most of
the limitations of additive manufacturing center around how to optimally orientate a
print to reduce support dependency and the likelihood of print failure. This allows
designers a large amount of design freedom and means that very complex
geometries can easily be created.
Complex and intricate designs can easily be produced by some 3D printing
technologies.
 Customization
Not only does 3D printing allow more design freedom it also allows complete
customization of designs. Because additive manufacturing is centered around building
single parts one at a time it is perfectly suited for one-off production. This concept has
been embraced by the medical and dental industry for the manufacture of custom
prosthetics, implants and dental aids. From high level sporting gear that is tailored to
fit an athlete perfectly to custom sunglasses and fashion accessories additive
manufacturing allows cost effective single run production of custom parts.
5.Ease of access-

22. 3D Printing
While additive manufacturing has been around for more than 30 years the majority of
growth has occurred in the last 5 years. This has lead to a large number of 3D
printers entering the industry making it significantly easier for designers to access
additive manufacturing technology. In 2015 alone more than 278,000 additive
manufacturing printers valued under $5000 were sold globally with the number of
printers sold doubling consistently for the last 3 years. What was originally a niche
technology accessible only to a small segment of the manufacturing industry is now a
readily available and cost competitive method of part production utilised in a vast
range of industries.
Number of printers under $5000 sold globally per year - Wohlers report 2015
6.Sustainability-
Subtractive manufacturing methods such as CNC milling or turning remove a
significant amount of material from an initial block resulting in high volumes of waste
material. Additive manufacturing methods generally only use the material needed to
build a part. Most processes use materials that can be reused for more than one build
resulting in additive manufacturing process producing very little waste.
The increase in number of additive manufacturing machines in the world has also
impacted the distance prototypes are shipped. Because 3D printers require a very
basic understanding to operate successfully, designs do not need to be sent away for
expert manufacture. The reduction in shipping requirements has a positive
environmental impact. This coupled with the ability to print and produce spare parts
on site results in a much smaller carbon footprint for most parts produced via additive
manufacturing.
7.Clear Communication-
Describing the product you are going to deliver is often misinterpreted since it leaves
construction up to the imagination. A conceptual picture of the product is better than
the description since it is worth 1,000 words, but getting to hold the tangible product-
to-be, in hand, clears all lines of communication. There is no ambiguity when holding
the exact, or at least a very close, representation of the product.
8.Feedback-
With a prototype you can test the market by unveiling it at a trade-show, showing it to
potential buyers or investors, or raising capital by pre-selling. Getting buyers response
to the product before it actually goes into production is a valuable way to verify the
product has market potential.
9.Personalize It-
With standard mass-production, all parts come off the assembly line or out of the
mold the same. With 3D printing, one can personalize, customize and tweak a part to
uniquely fit their needs, which allows for custom fits in the medical and dental
industries and helps set people apart in the fashion and jewelry world.
10.Build your Imagination-
In the modern boom of digital art and design, the possibilities are not only
accelerating but limitless. One can now 3D print almost anything they imagine after

23. 3D Printing
drawing it up virtually. In a relatively short time, an idea, concept, dream or invention
can go from a simple thought to a produced part that you can hold.
Other Advantages of 3D Printers:
When you choose to use a 3D printer over more traditional manufacturing methods,
the list of resulting benefits is quite long. From significant cost savings and faster
production times to more creative freedom and a decreased carbon footprint, there is
no shortage of advantages with this manufacturing method.
1.Reduced overhead costs-
A 3D printer reduces your overhead costs significantly, and in more ways than one.
First, it cuts down on material costs. Instead of using a big block of plastic, metal or
other material and cutting the product out of it (subtractive manufacturing,) you’re able
to use only the materials absolutely necessary for the build (additive manufacturing).
This not only cuts your upfront costs for materials, it also reduces the funds you’d
normally spend on transporting and disposing of that waste.
2.Greater creativity-
This is one of the best advantages of 3D printers. Unlike with traditional
manufacturing methods, you’re not limited by your workforce or the machines you’re
using. A 3D printer lets you create virtually anything you can imagine. Use any plastic,
metal, ceramic, glass or alloy material you want, and get creative with colors, intricate
details or anything else your product requires.
3.Creation of small-scale, lightweight models and prototypes-
Many products are just too large or bulky to take on sales calls. Unfortunately, that
can make closing deals difficult. Buyers want to see and feel a product before they
invest in it; otherwise, it’s just not worth the risk. Thankfully, this is yet another area
where a 3D printer can help. With one, you can easily and quickly produce detailed,
to-scale models and prototypes of larger products, parts and components. Then your
team can take them on sales calls, to pitch meetings and more to ensure they make
that sale.
4.Faster product delivery-
The 3D printing process can be completed anywhere in the world as long as a printer
is available. That means you can produce your products locally, right where your
customers live. For example, if a product is ordered in Canada, a 3D printing facility in
Canada can receive your product design, print it out and ship it from there. Then you
don’t have to pay costly shipping or customs fees, and your customer gets the
product quickly, easily and affordably.
DISADVANTAGES OF 3D PRINTING:
1.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.
2.Limited Size –

24. 3D Printing
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.
3.Limited Raw Materials –
Traditional manufacturing of products has an enormous range of raw materials that
can be 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.
4.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.
5.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.
6.Size-
Parts printable by a 3D printer are limited by the size of the printer itself. The chamber
sizes of commercially available (and affordable) 3D printers, which are commonly
small in size enough to be transportable and fit right on your desktop, are
proportionately small. The larger models, capable of printing larger shapes and parts,
are ordinarily very expensive. Also large parts can take a long time to print on current
technology.
7.Accuracy-
As it stands, parts printed with 3D printing technology are prototypes and test parts
most of the time. In order engineers to be able to validate whether or not the
prototype or test part is be viable, the dimensions have to be to within a degree of
accuracy not yet achievable on the most cutting edge technology. Despite recent
advances, most of the materials used in 3D printing still necessitate a disclaimer for
the levels of accuracy- there is a margin of around .1 of a millimeter in many cases,
which constitutes a catastrophic mistake in many fields of engineering.
8.Materials-
Limited- ceramics, resin, plastics can be used. Plastic works for the most part, but
can’t have its strength tested in many cases because of the varying melting
temperatures. Metal is sometimes usable but dense metal is out of the question,
meaning fragility is an issue. Glass and gold are utilized by some specialist
companies but are sure not to become commercially available.
Other Disadvantages Include:
Jobs in manufacturing will be rendered obsolete, in direct correlation to
advancements in 3D printing (although design will become a flourishing field); having
a negative impact on third world economies.

25. 3D Printing
There isn’t much happening in the way of recycling initiatives for 3D printing.It will be
hard or impossible to deter or control people from 3D printing potentially dangerous
items including 3D knives, 3D guns , even 3D explosives are doubtlessly imminent.
Copyright infringements will be rife when the counterfeit printing of copyrighted or
patented products and designs becomes widespread and difficult to identify or
prevent.
FREE 3D DESIGNING SOFTWARES:
Autodesk 123D Design
Easy-to-use yet powerful modeling tool with library of existing components or the
ability to create from scratch. Also available for the iPad. Integrated and prints directly
to Shapeways.

26. 3D Printing
Tinkercad
A fantastic beginner program, that leads you to learn complex things through simple
quests. Runs right in your browser, and the skills you learn are easily transferable to
more advanced programs. Integrated and prints directly to Shapeways.
3D Tin
Another browser based program using WebGL, this is free as long as you share your
designs under Creative Commons.
Blender
A powerful application with full-fledged professional tools, Blender has a wide
community and resources to help you learn.
FreeCAD
An open source parametric 3D modeler, great for both the home user, hobbyist and
experienced designer. Parametric modeling allows for easy editing of your design.
Open SCAD
OpenSCAD is not an interactive 3D design tool. It is something like a programmatic
3D-compiler that reads a script file containing 3D geometry definitions, and in turn
generates a solid 3D model as output.
Sculptris
A free, introductory digital sculpting tool, a great stepping stone for digital sculptors,
created by the makers of Zbrush.
Sketchup
Drawing-based tool for architects, designers, builders, makers and engineers who
design for the physical world. SketchUp Make is a free version and SketchUp Pro is a
paid version with additional functionality.
3D Model To Print

27. 3D Printing
A cloud-based software service, focused on 3D architectural models. 3DMTP
automatically and efficiently transforms 3D designs into scalable and 3D printable
model files.
eMachineShop
Easy-to-use for designing mechanical parts - a machine shop at your fingertips! With
its intuitive interface & helpful videos, anyone can leverage both the Shapeways and
eMachineShop production facilities by using just one tool.
Commercial3D Design Softwares:
3D Studio Max
An extensive suite of 3D design tools, with a unique and intuitive interface.
AutoCAD
An advanced design and documentation tool. Ideal for architects and design
engineers.
Cinema 4D
A well known design Suite in the VFX community, it has great tools for 3D modeling
for printing as well.
Lightwave 3D
A classic 3D graphic software, which includes powerful rendering, animation and
modeling tools.
Autodesk Maya
A massive, complete suite of tools for professional all aspects of 3D design including
modeling, rigging, dynamics and animation.
Photoshop CC
The Industry standard software for 2D content editing
and creation applied to 3D design. Offers integration
directly with Shapeways.

28. 3D Printing
Rhinoceros
Very popular curve based modelling software.
ZBrush
A popular, advanced 3D sculpting tool with a powerful voxel-based system.
Most common and Universal file format for 3D printing:
STL - Stereolithography
VRML - Virtual Reality Modeling Language
Additive Manufacturing File Format (.AMF)- is a new XML-based open standard for
3D printing.
GCode-Is another file format input for 3D printers

29. 3D Printing
DIFFERENCE BETWEEN 3D PRINTING &
TRADITIONAL MANUFACTURING TECHNOLOGIES:
3D printing, or additive manufacturing, has been the focus of some strong
discussions in the manufacturing industry in the last few years. While the concept of
3D printing has been around for a while, new advancements in the technology have
started to lower the cost of the process to levels that make it more feasible for general
manufacturing use.
The process of using specialized equipment to assemble an object layer by layer has
some unique and interesting advantages over traditional manufacturing. However, will
3D printing truly replace more traditional methods of assembling products?
Prototype Production
One of the biggest advantages that 3D printing over traditional manufacturing is that
the 3D printing process generally doesn’t require any special new tooling to make a
part. When making a prototype, this can save a lot of time, money, and effort that
would normally be spent on tooling the production line and getting an assembly
process set up.
If the prototype reveals that the design needs rework, a new design can be
programmed into the 3D printer and created relatively fast, while a traditional
assembly line would require lots of time to retool the line just to churn out a small
handful of prototype parts, which would be a waste of time, material, and labor.
So, when it comes to making a limited-run prototype of a part, 3D printing has a clear
edge over the traditional method of tooling an entire production line.
Waste prevention
Another key advantage of using 3D printing over many traditional production
processes is that it is incredibly resource-efficient. With a 3D printer, the only material

30. 3D Printing
that is consumed is what passes through the extruder of the printer, which is used for
the actual assembly of the product.
Compare this to injection-molds, which often require the use of extra materials to fill
the mold. Perforated sheet metal assembly processes will take a whole piece of sheet
metal and cut holes into it, leaving the material that once filled each hole as scrap.
Now, this scrap material is usually recycled, but it adds extra time and labor to the
manufacturing process.
In many cases, additive manufacturing processes will produce less waste
than traditional manufacturing would.
Additionally, manufacturers don’t have to produce as much of a given roduct to
justify the setup costs. As noted in a World Finance article on 3D printing,
“Whereas the traditional supply chain relies on the efficiencies of mass production
and requires a high volume of assembly workers, additive manufacturing needs little
more than the necessary raw material to fulfil any one order an the necessary
blueprint to produce it.”
Large-ScaleProduction
When you’ve moved past the prototyping phase and need to start producing parts at
speed, the additive manufacturing process is generally less efficient and reliable than
other, more traditional methods of making Parts.
While 3D printers might not need to be retooled in between production runs, the
speed at which a 3D printer can assemble an object often pales in comparison to the
traditional assembly line.
This is because 3D printing requires each object to be assembled one layer at a time,
with each new layer being directly placed on top of the previous one. Even with a
“fast” 3D printer, some small objects can take hours to make.
As pointed out on the 3D Genius FAQs page, a “pair of nut crackers took nearly 3
hours to print.” Injection molding the plastic parts and assembling them in a traditional
production line would allow for dozens or hundreds of identical nutcrackers to be
made in that amount of time.
So, while 3D printing has a much shorter lead time, it cannot currently compete with
traditional manufacturing’s speed for mass production.
Availability of Specific Materials
Thanks to some recent advancements in 3D printing such as Selective Laser
Sintering, 3D printing can now be used to make objects out of some metals, as well
as polymers. However, the use of specific materials requires different models of 3D
printers that are designed for those materials. Additionally, some metal alloys still
cannot be worked in a 3D printer with great quality or consistency because of their
high melting points.
This can be a limiting factor when specific materials are needed for a given part.

31. 3D Printing
Scale of ProducedParts
The manufacture of certain large-scale parts can be very difficult with 3D printing
compared to traditional manufacturing processes.
With 3D printers, you’re restricted to the total area of the printing bed for making any
given part. Depending on the model of 3D printer you use, this could be a few cubic
inches or a few cubic feet.
Now, 3D printers can allow you to create a part in pieces for later assembly, but doing
so may not be ideal. Not only does this mean using labor for the final assembly of the
part (negating the low labor use advantage), it may create stress points in a part that
needs to be solid to work at peak performance.
Theconclusion
Overall, the use of 3D printing isn’t likely to completely replace traditional
manufacturing any time soon.
However, the technology does have incredible utility for small, one-off production runs
and the manufacture of small custom work pieces that would normally need a lot of
specialized tooling to make.
In addition of these points some importantpoints are also as
1- Using only one type of polymers usually (ABS polymer) in 3D but in other
Processes you can use what you want.
2-The 3D printed parts are not strong, they are just for sake of Prototyping.
3-3D can do complex shapes with less cost than the traditional machining.
4-Traditional machining needs skillful workers but the 3D printing need just he CAD
design of the product.
5- No need of different tools for the production of different parts.

32. 3D Printing
33 Best Sites for Free 3D Printer Models & STL Files
to 3D Print:
Site Type Free/Paid #Models #Visitors
Thingiverse Repository Free ★★★★★ ★★★★
GrabCAD Repository Free ★★★★★ ★★★
Sketchfab Repository Free ★★ ★★★
CGTrader Marketplace Free, Paid ★★★ ★★★
MyMiniFactory Marketplace Free ★★★ ★★★
Yeggi Search Engine Free, Paid n/a ★★★
Pinshape Marketplace Free, Paid ★★★ ★★★
XYZprinting3D Gallery Marketplace Free, Paid ★★★ ★★★
Dremel Idea Builder Repository Free ★★ ★★★
YouMagine Repository Free ★★★ ★★★
Yobi3D Search Engine Free n/a ★★
STLFinder Search Engine Free, Paid n/a ★★
3DExport Marketplace Free, Paid ★★★ ★★
Cults3D Marketplace Free, Paid ★★ ★★
Zortrax Library Repository Free ★★ ★★
New Matter Repository Free ★★ ★★

33. 3D Printing
Site Type Free/Paid #Models #Visitors
Rinkak Marketplace Free, Paid ★★ ★★
3DKitBash Marketplace Free, Paid ★★ ★★
3DShook Subscription Service Free, Paid ★★ ★★
RascomRas Repository Free ★ ★★
Threeding Marketplace Free, Paid ★★ ★★
Repables Repository Free ★ ★★
Libre3D Repository Free ★ ★
3Dagogo Marketplace Free, Paid ★ ★
Shapetizer Marketplace Free, Paid ★ ★
The Forge Repository Free ★★ ★
Redpah Marketplace Free, Paid ★★ ★
Polar Cloud Repository Free ★★ ★★
3D Warehouse Repository Free ★ ★★★★
STLHive ShopFree, Paid Free, Paid ★ ★
NASA Repository Free ★ ★★★★
NIH 3D Print Exchange Repository Free ★★★★★ ★★★★
Instructables Repository Free ★★ ★★★★★

34. 3D Printing
3D PRINTING’S EFFECT TO OUR ENVIRONMENT:
3D printing is just one of the many advances in technology that will lead to a
healthier environment around the world. Here are three major ways in which this
technology will usher in a cleaner, purer, safer world around us:
#1 Wide Spread Recycling at Our Fingertips
In the Late 80’s and early 90’s we saw a major shift towards recycling waste.
Curbside bins were handed out to residents in most areas around the nation, and
people began to think twice before throwing out certain items. 1-plasticThis was due
to advances in technology allowing for recycling plants to flourish. Fast forward 20-
30 years and we are at the starting line of another major recycling revolution.
Plastics, as well as eventually metals and other materials can be ground up and
turned into filament for 3D printers. Over the last year or so, there has been a
movement underway to do this. Perpetual Plastic is one of these movements, as well
as others like the Filabot, which received over 300% of it’s goal in funding on
Kickstarter back in 2012. Basically anyone with the proper tools can throw a used
plastic bottle into a machine, and after a few steps turn that into any of tens of
millions of different items. If that’s not something to get excited about, nothing is.
Scientists as well as do-it-yourselfers are also working with metals, wood materials,
and glass to push forward similar initiatives.
#2 Reduction in Fossil Fuel Use From Shipping
Every day millions of barrels of oils are used shipping items across the world.
Whether it’s a UPS truck, Fedex 747, freight train, or cargo ship, global trade is a
huge business. Millions of people every day order off of 1-planeinterest sites like
Amazon, and receive their products within 2 days time. That takes a lot of fuel.
Where there is fuel, there is pollution. 3D printing is already helping to cut back on
shipments in many industries. Thus far, it’s barely made a dent in the amount of fuel

35. 3D Printing
needed each day within the shipping industry, however, trends show it will make a
significant dent within the coming decade. Today you can 3D print your child a toy,
yourself a smartphone case, or your loved ones jewelry, instead of having to order
those items online and paying to have them shipped, or jumping into your vehicle
and running to the local Walmart. In the future, almost everything will be able to be
printed out, cutting costs, saving time, and most importantly preserving the
environment.
#3 Far Less Waste
Finally, 3D printers are cutting back on waste within the manufacturing industry. 3D
printing is also known as “additive manufacturing.” That’s because it does just that,
slowly adds material to an item until it is complete. Most other manufacturing
methods are subtractive. For instance, when you build a chair out of wood, you don’t
use ever single shred of lumber in that chair. You have scraps as well as saw dust
left over. Same thing for
1-grassjust about anything that is manufactured these days. You almost always
have waste material, which nine times out of ten, winds up in a landfill, or
somewhere even worse. 3D printers will save money for manufacturers, but most
importantly cut back substantially on waste. Many companies include General
Electric, Apple, and Ford are already using, or have plans to use 3D printing within
their manufacturing facilities.
IS 3D PRINTING ECO-FRIENDLY TECHNOLOGY ?
The reality today does not allow the 3D printing technology to be fully Eco-friendly.
Different researchers reveal that this technology uses large amounts of energy,
larger than the amount used by milling and drilling machines. A research (Atkins
Project) done at Loughborough University in the United Kingdom revealed that to
produce the same object of the same weight, some 3D printing processes require 50
to 100 times more electrical energy than injection molding machine.
Another setback is the heavy reliance on plastic materials for the printing process.
Plastic as a whole is not considered an Eco-friendly material. Studies show that
industrial grade 3D printers have a substantial plastic byproduct left behind that in
most cases is not suitable for reuse.
Most people are afraid of technology, in that they feel it will lead to the worlds
demise. In my opinion technology will solve some of the most unsolvable problems
we face today. Embrace it to the fullest!

36. 3D Printing
THE FUTURE OF 3D PRINTING:
Moving from prototype to tooling 3D printing has expended to full-scale end-part
production and replacement part production.
3D printing is moving in several directions at this time and all indications are that it
will continue to expand in many areas in the future. Some of the most promising
areas include medical applications, custom parts replacement, and customized
consumer products. As material improve and costs go down, other applications we
can barely imagine today will become possible.
Be it a 3D printed bionic ear enabling you to hear beyond human hearing
frequencies, 3D printing your dream house in just a few hours – 3D printing is
revolutionizing every walk of life.
According to Wohlers Report 2014, the worldwide revenues from 3D printing are
expected to grow from
$3.07 billion in 2013 to
$12.8 billion by 2018, and
exceed $21 by 2020.
In the field of medicine, 3D
printing of complex living
tissues, commonly
known as bioprinting, is
owning up new avenues
for regenerative
medicine.
With an improved
understanding of this technology, researchers are even trying to catalyze the natural
healing mechanism of the body by creating porous structures that aid in bone
stabilization in the field of orthopedics. Even intricate human body parts like the brain
can be replicated using the 3D technology to aid in complex medical surgeries
through simulation.
Some companies are investigating the possibility of printing organic materials; these
materials could be used in a much wider array of surgeries and potentially replace a
much larger selection of defective human parts. Expect expansion of training
techniques based on 3-D printed models of complex human systems, a greater effort
to more explicitly explain surgeries or the workings of the human body to patients as
detailed replicas of body parts to become more common, and more precise surgical
and diagnostic equipment based on designs that can be printed but not
manufactured using traditional means.
There is certainly a market for customized keepsakes and 3-D printing can take that
industry to new heights. Shapeways is already marketing several basic designs of
customized keepsakes using either personalized text or photographs supplied by the
customer.

37. 3D Printing
There may come a time when choosing new cutlery doesn’t involve selecting a
pattern at the store but designing it on your computer and printing out the resulting
pieces. One day we may dial up just the right level of edge for a child starting to use
sharp knives, build customized economic handles that fit each individual’s and
perfectly.
Another area of growth in the 3-D printing arena is replacement parts production.
Need a new screw, a new gear or a new piston for your car? Instead of trying to
track down the parts, pay for shipping, and waiting weeks for its arrival, you’ll just
able to print it out and go. Mechanics will keep specs for every part of every car ever
sold in a database and print out whatever they need immediately with no difficulty.
While it would save time and money for your part.
Another intriguing area is customized food production. Evil Mad Scientist
Laboratories has created a low cost, low resolution capable of printing models made
from ordinary granulated sugar. We could soon see edible centerpieces, customized
candy gifts, novelty lollipops customized for gifts shops attached to tourist
attractions.
Manufacturers are adopting this technique as it reduces coast & complexity of the
product.
It has no limits of uses in the industries. This technique has a lead participation in the
revolution of the industry in the future.
REFERENCES:
https://www.youtube.com/watch?v=G0EJmBoLq-g
https://youtu.be/BqCA2vfj2Wc
https://sustainabilityworkshop.autodesk.com/blog/environmental-impacts-3d-
printing
https://consumables.ic3dprinters.com/3d-printer-job-cost-calculator/