3D Printing Lab Manual

Introduction
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 down successive layers of
material until the entire object is created. Each of these layers can be seen as a thinly sliced
horizontal cross-section of the eventual object.

Working

It all starts with making a virtual design of the object you want to create. This virtual
design is made in a CAD (Computer Aided Design) file using a 3D modeling program (for the
creation of a totally new object) or with the use of a 3D scanner (to copy an existing object). A
3D scanner makes a 3D digital copy of an object. To prepare a digital file for printing, the 3D
modeling software “slices” the final model into hundreds or thousands of horizontal layers.
When the sliced file is uploaded in a 3D printer, the object can be created layer by layer. The
3D printer reads every slice (or 2D image) and creates the object, blending each layer with
hardly any visible sign of the layers, with as a result the three dimensional object.

Types of 3D Printing Techniques

Not all 3D printers use the same technology. There are several ways to print and all
those available are additive, differing mainly in the way layers are build to create the final
object.

To be more precise: since 2010, the American Society for Testing and Materials (ASTM)
group “ASTM F42 – Additive Manufacturing”, developed a set of standards that classify the
Additive Manufacturing processes into 7 categories according to Standard Terminology for
Additive Manufacturing Technologies:

1. Vat Photopolymerisation
2. Material Jetting
3. Binder Jetting
4. Material Extrusion
5. Powder Bed Fusion
 6. Sheet Lamination
7. Directed Energy Deposition

1. Vat Photopolymerisation

This technique was invented in 1986 by Charles Hull, who also at the time founded the
company, 3D Systems.

Vat photopolymerisation

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.

2. Material Jetting

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.
 Material Jetting

3. Binder Jetting

With binder jetting two materials are used: powder base material and a liquid binder.
In the build chamber, powder is spread in equal layers and binder is applied through jet nozzles
that “glue” the powder particles in the shape of a programmed 3D object. The finished object
is “glued together” by binder remains in the container with the powder base material. After the
print is finished, the remaining powder is cleaned off and used for 3D printing the next
object. This technology was first developed at the Massachusetts Institute of Technology in
1993 and in 1995 Z Corporation obtained an exclusive license.
4. Material Extrusion

The most commonly used technology in this process is Fused Deposition Modeling
(FDM). The FDM technology works using a plastic filament or metal wire which is unwound
from a coil and supplying material to an extrusion nozzle which can turn the flow on and off.
The nozzle is heated to melt the material and can be moved in both horizontal and vertical
directions by a numerically controlled mechanism, directly controlled by a computer-aided
manufacturing (CAM) software package. The object is produced by extruding melted material
to form layers as the material hardens immediately after extrusion from the nozzle.

Fused deposition modelling (FDM), a method of rapid prototyping: 1 – nozzle ejecting molten
material (plastic), 2 – deposited material (modelled part), 3 – controlled movable table

This technology is most widely used with two plastic filament material
types: ABS(Acrylonitrile Butadiene Styrene) and PLA (Polylactic acid) but many other
materials are available ranging in properties from wood filed, conductive, flexible etc.

FDM was invented by Scott Crump in the late 80’s. After patenting this technology he started
the company Stratasys in 1988. The software that comes with this technology automatically
generates support structures if required. The machine dispenses two materials, one for the
model and one for a disposable support structure.

5. Powder Bed Fusion

The most commonly used technology is Selective Laser Sintering (SLS). This technology uses
a high power laser to fuse small particles of plastic, metal, 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 (or layers) generated by the 3D modeling program on
the surface of a powder bed. After each cross-section is 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.

Selective Laser Sintering

All untouched powder remains as it is and becomes a support structure for the object. Therefore
there is no need for any support structure which is an advantage over 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.

6. Sheet Lamination

Layer Object Manufacturing

7. Directed Energy Deposition

This process is mostly used in the high-tech metal industry and in rapid manufacturing
applications. The 3D printing apparatus is usually attached to a multi-axis robotic arm and
consists of a nozzle that deposits metal powder or wire on a surface and an energy source (laser,
electron beam or plasma arc) that melts it, forming a solid object.

Direct Energy Deposition with metal powder

Design

Flow Chart for 3D Printing

Thermo physical properties of PLA (Polylactic acid)

 Melting point: around 180°C to 250°C

 Bed Temperature: 50°C to 60°C

Thermo physical properties of ABS (Acrylonitrile butadiene styrene)

 Melting point: around 230°C

 Bed Temperature: 110°C

Process Parameters

1. Extruder temperature

2. Speed of the nozzle

3. Nozzle diameter

4. Slicing thickness

Characterization study

1. Micro structural analysis using optical microscope

2. Harness testing

Results and Discussion

Compare the microstructure and hardness of the specimen in different process

Summary