UNIT – 2

PART -B

1) Classify the various materials used for the applications in 3D printing. Also
compare them based on its limitations
Classification of Materials Used in 3D Printing
1. Thermoplastics
o Examples: PLA, ABS, PETG, Nylon, TPU (flexible filament).
o Applications: Prototypes, functional parts, toys, and medical models.
2. Photopolymers
o Examples: Standard resin, tough resin, flexible resin.
o Applications: Dental molds, jewelry, and high-detail models.
3. Metals
o Examples: Stainless steel, aluminum, titanium, cobalt-chromium.
o Applications: Aerospace, automotive, and medical implants.
4. Composites
o Examples: Carbon fiber-filled, glass-filled, or wood-filled filaments.
o Applications: Structural parts, lightweight yet strong components.
5. Ceramics
o Examples: Alumina, zirconia, silica-based materials.
o Applications: Art, high-temperature applications, and medical devices.
6. Biomaterials
o Examples: Biocompatible resins, bio-inks, and PCL (Polycaprolactone).
o Applications: Tissue engineering, prosthetics, and medical implants.
7. Others
o Examples: Wax, sand, and food-grade materials like chocolate or sugar.
o Applications: Casting molds, artistic creations, and food prototyping.
Comparison of Materials Based on Limitations

Material Type Limitations

Limited heat resistance (e.g., PLA); warping and odors during printing (e.g.,
Thermoplastics
ABS).

Brittle and prone to cracking; requires post-curing; sensitive to UV light

Photopolymers
degradation.

Expensive materials and equipment; requires post-processing; limited

Metals
geometries in some methods.

Composites Abrasive to printer nozzles; higher cost compared to pure filaments.

Ceramics Brittle and prone to breakage; high-temperature processing required.

Limited mechanical properties; strict handling requirements for

Biomaterials
biocompatibility.

Others (e.g., Limited functional strength; used mainly for niche applications like molds
Wax) or artistic designs.

This classification highlights the broad range of materials available for 3D printing and their
specific limitations depending on application requirements.

2) Discuss the principles of laminated object manufacturing (LOM) in 3D

printing. Evaluate its advantages, limitations, and typical use cases
Principles of Laminated Object Manufacturing (LOM)

Laminated Object Manufacturing (LOM) is an additive manufacturing technique that involves

stacking and bonding layers of material to create a 3D object. Each layer is cut to shape based
on the 3D model, and successive layers are bonded to form the final structure. Here's how it
works:
1. Material Layering: A sheet of material (such as paper, plastic, or metal) is fed into the
build platform.
2. Adhesion: The material layer is bonded to the previous layer using adhesive or heat.
3. Cutting: A laser or a blade cuts the outline of the desired shape for the layer.
4. Waste Removal: Excess material is either peeled away manually or left in place to
support the structure during printing.
5. Repeat: The process continues until the full 3D object is completed.
Advantages of LOM

1. Cost-Effectiveness: Materials like paper or plastic sheets are inexpensive compared to

other 3D printing materials.
2. Fast Processing: Large objects can be produced relatively quickly because it doesn’t rely
on complex extrusion or powder-based methods.
3. Minimal Material Restrictions: Can use a variety of materials, including paper, plastic,
and composite materials.
4. No Need for Supports: Excess material can act as support during the build, eliminating
the need for additional support structures.
5. Good for Large Parts: LOM is suitable for producing large-scale objects.

Limitations of LOM

1. Lower Strength: Bonded layers may not provide as much structural integrity as other 3D
printing methods like SLS or FDM.

2. Surface Finish: The finished product often requires post-processing for a smoother
surface.

3. Material Waste: Excess material around the final object can lead to waste if not
recycled.
4. Limited Material Choices: Although versatile, it doesn't support materials with high-
performance properties like metals or ceramics.
5. Accuracy: Dimensional accuracy is often lower compared to methods like SLA or DLP.
6. Complexity: Intricate geometries and internal cavities are harder to achieve compared
to powder-based methods.

Typical Use Cases of LOM

1. Prototyping: Ideal for creating large-scale, low-cost prototypes for visualization and
design evaluation.
2. Architectural Models: Used for building architectural models with detailed textures.
3. Pattern Making: Useful for making patterns or molds for casting processes.
 4. Packaging and Design: Suitable for creating product packaging or mock-ups.

Evaluation Summary
Laminated Object Manufacturing is a fast and cost-effective method for producing large-scale
models and prototypes. However, its limitations in material strength and accuracy make it less
suitable for functional parts or intricate designs. It is best used for applications where low cost
and speed are priorities over mechanical performance.

3) Outlline the material selection process in 3D printing with a suitable

example.
Material Selection Process in 3D Printing
The material selection process for 3D printing involves systematically
evaluating the requirements of the application and matching them with the
properties of available materials. Below is an outline of the steps involved:

1. Define Application Requirements

Identify the key performance characteristics required for the specific
application, such as:
 Mechanical Properties: Strength, flexibility, durability.
 Thermal Properties: Heat resistance or conductivity.
 Chemical Properties: Corrosion or solvent resistance.
 Aesthetic Requirements: Color, finish, or texture.
 Regulatory Requirements: Biocompatibility or food safety, if applicable.
Example: For a drone frame, the material must be lightweight, strong, and
impact-resistant.

2. Evaluate Printing Technology

Each 3D printing technology supports a specific set of materials. Match the
requirements to the printing technology:
 FDM: Thermoplastics like PLA, ABS, PETG.
 SLA/DLP: Photopolymers for high-detail objects.
 SLS/DMLS: Powder-based metals and plastics for durable and functional
parts.
Example: For a drone frame, FDM or SLS could be suitable for lightweight and
durable materials.

3. Select Material Based on Properties

Compare materials based on key properties, such as:
 Tensile Strength
 Flexural Modulus
 Heat Deflection Temperature (HDT)
 Impact Resistance
 Cost
Example: For the drone frame, Nylon with carbon fiber reinforcement would
be a good choice for high strength-to-weight ratio and durability.

4. Consider Cost and Availability

Assess the cost of the material and its compatibility with available printers.
Choose a material that balances performance and budget.
Example: If Nylon with carbon fiber is too expensive, PETG could be a cost-
effective alternative.

5. Test and Validate

Prototype the part using the selected material to evaluate its performance.
Make adjustments if necessary based on the testing results.
Example: Test the drone frame for weight, impact resistance, and durability. If
it fails under stress, switch to a stronger material like polycarbonate (PC).

Example Application: Drone Frame

1. Requirements:
o Lightweight for flight efficiency.
o High strength to withstand impacts.
o Resistance to outdoor conditions like UV exposure.
2. Technology:
o FDM for cost-effective thermoplastics or SLS for reinforced
composites.
3. Material Options:
o PLA: Lightweight but brittle, unsuitable for impacts.
o PETG: Good impact resistance and weatherproofing.
o Nylon with carbon fiber: Strong and lightweight, ideal for demanding
applications.
4. Final Selection:
o Nylon with carbon fiber for high performance.
5. Validation:
o Test the frame in real flight conditions. If successful, proceed with
mass production.
By following this process, the material can be selected effectively to meet the
functional, aesthetic, and economic requirements of the project.
4) a) Illustrate the process of wire extrusion and its application in metal
fabrication.
 (a) Process of Wire Extrusion and Its Application in Metal Fabrication
Wire Extrusion Process:
Wire extrusion is a metal fabrication process that involves reducing the
diameter of a metal wire or rod by forcing it through a die. Here's how the
process works:
1. Raw Material Preparation:
o Metal rods or billets are heated to make them more malleable (if hot
extrusion is used).
o For cold extrusion, the material is processed at room temperature,
often requiring lubrication to reduce friction.
2. Die Setup:
o A die with the desired cross-sectional shape is mounted in the
extrusion machine.
3. Extrusion:
o The metal rod is pushed or pulled through the die using mechanical
or hydraulic force.
o The diameter is reduced, and the wire takes on the shape of the die
opening.
4. Cooling and Coiling:
o The extruded wire is cooled using water or air.
o It is then coiled for storage or further processing.
Applications in Metal Fabrication:
 Production of electrical wires, cables, and fasteners.
 Manufacturing of metal meshes, springs, and structural reinforcements.
 Used in additive manufacturing processes like Wire Arc Additive
Manufacturing (WAAM).

4)b) Compare the material selection process for plastics and metals in
additive manufacturing and explain the factors influencing their suitability
for different applications.
(b) Comparison of Material Selection for Plastics and Metals in Additive
Manufacturing
Aspect Plastics Metals

Lightweight, flexible, and High strength, durability,

Material corrosion-resistant. Ideal and heat resistance.
Properties for prototypes and non- Suitable for functional and
structural parts. load-bearing parts.

Cost Generally less expensive. Significantly higher cost.

Printing FDM, SLA, and SLS are SLM, DMLS, and WAAM
Technology commonly used. are preferred methods.

Requires high-energy
Thermal Low melting points (e.g.,
sources (e.g., lasers or
Considerations PLA, ABS).
arcs).

Easier to print with lower Requires advanced printers

Ease of Printing
equipment costs. and expertise.

Extensive post-processing
Minimal post-processing
Post-Processing (e.g., heat treatment,
required.
machining).

Toys, medical models, and Aerospace, automotive,

Applications
consumer products. and medical implants.

Factors Influencing Suitability for Applications

Plastics:
1. Complex Geometries: Plastics are well-suited for intricate designs due to
ease of shaping.
2. Cost Sensitivity: Chosen for low-budget projects or disposable prototypes.
3. Environmental Conditions: Used for applications not requiring high thermal
or mechanical resistance.
4. Regulatory Needs: Biocompatible plastics like PLA for medical applications.
Metals:
1. Mechanical Requirements: Selected for strength, wear resistance, or load-
bearing applications.
2. Thermal Resistance: Suitable for parts exposed to high temperatures, such
as engine components.
3. Longevity: Used for durable, long-term functional parts.
4. Industry Standards: Aerospace and medical industries often mandate the
use of metals for safety-critical components.

Example:
 For a prosthetic limb, plastic like PETG may be used for lightweight
components, while metal like titanium is chosen for load-bearing joints.
 In automotive, plastic may be used for aesthetic interior parts, while metal
is used for engine components.
This comparison highlights how specific material properties and application
demands guide material selection in additive manufacturing.
5) Illustrate the principle of extrusion and photopolymerization with suitable
sketches.
Principles of Extrusion and Photopolymerization in 3D Printing

1. Principle of Extrusion
Extrusion is the process used in Fused Deposition Modeling (FDM), where
thermoplastic materials are melted and deposited layer by layer to create a 3D
object.
Process Steps:
1. Material Feeding: A thermoplastic filament is fed into a heated nozzle.
2. Melting: The filament is melted in the nozzle.
3. Deposition: The molten material is extruded onto the build platform or
previous layers in a pre-defined path, solidifying as it cools.
4. Layer-by-Layer Building: The process is repeated layer by layer until the
object is complete.
Applications:
 Prototypes, functional parts, and low-cost manufacturing.

2. Principle of Photopolymerization
Photopolymerization is used in technologies like SLA (Stereolithography) and
DLP (Digital Light Processing). It involves the curing of liquid resin into solid
form using a light source.
Process Steps:
1. Resin Layer Preparation: A thin layer of liquid photopolymer resin is spread
over a build platform.
2. Light Exposure: A UV laser (SLA) or projector (DLP) selectively cures the
resin in a specific pattern based on the design.
3. Layer Building: The platform lowers, and a new resin layer is applied and
cured. This continues until the object is complete.
4. Post-Processing: The printed object is cleaned and often cured further to
enhance strength.
Applications:
 High-detail prototypes, dental models, jewelry, and functional components.

Illustrative Sketches
I will describe each for clarity:
1. Extrusion:
 o A nozzle deposits melted plastic filament onto a platform, layer by
layer, to build the object. The sketch shows the filament spool,
heated nozzle, and the building platform.
2. Photopolymerization:
o A UV light source cures specific regions of liquid resin on a build
platform. The sketch highlights the resin tank, UV laser/projector, and
the build platform lowering into the tank.
6) a) Show the limitations of using biological tissues and hydrogels in 3D
printing, and also the process of material selection for biomedical
applications.
(a) Limitations of Using Biological Tissues and Hydrogels in 3D Printing
Limitations:
1. Mechanical Weakness:
o Hydrogels and biological tissues lack the mechanical strength
required for load-bearing applications.
o They are prone to deformation and tearing during printing or post-
processing.
2. Biocompatibility Issues:
o Some synthetic hydrogels may not be fully biocompatible, leading to
immune responses.
o Incorporating living cells in bio-inks can be challenging due to their
sensitivity to printing conditions.
3. Degradation:
o Hydrogels are often biodegradable, but the degradation rate may not
align with the intended application.
o Maintaining long-term structural integrity is difficult.
4. Printing Challenges:
o Limited viscosity range for extrusion or droplet-based techniques.
o Requires precise temperature and pressure control.
5. Nutrient Diffusion:
o Difficulty in ensuring sufficient nutrient diffusion for cell viability in
3D structures.
o Thick constructs often suffer from cell death at the core.
 6. Cost and Scalability:
o Bio-inks and specialized printers are expensive, limiting widespread
adoption.
o Printing large, functional tissues remains a challenge.

Material Selection for Biomedical Applications

The selection process involves these steps:
1. Identify Application Requirements:
o Mechanical properties (strength, flexibility).
o Biocompatibility and degradation behavior.
o Specific requirements like osteoconductivity for bone scaffolds.
2. Choose Material Type:
o Natural Polymers: Collagen, gelatin, alginate for biocompatibility.
o Synthetic Polymers: PLA, PCL for controlled degradation rates.
o Hydrogels: PEG-based or hybrid hydrogels for soft tissue applications.
o Composites: Hydroxyapatite-filled scaffolds for bone tissue
engineering.
3. Evaluate Printing Method:
o Ensure compatibility with extrusion, SLA, or bioprinting methods.
o Consider process-specific requirements like curing and temperature
control.
4. Prototyping and Testing:
o Test materials for cytotoxicity, mechanical strength, and in-vitro
performance.

6) b) Demonstrate the lamination process to fabricate objects from fiber and

wood materials in additive manufacturing.

(b) Lamination Process to Fabricate Objects from Fiber and Wood

Materials
Process Steps:
1. Material Preparation:
 o Sheets of fiber or wood material are prepared. These can be natural
wood veneers, paper, or composite fiber sheets.
2. Adhesive Application:
o An adhesive layer is applied between the sheets to bond them
together. For wood, glue or resin is used; for fibers, epoxy or
thermoplastics can act as binders.
3. Layer Stacking:
o The sheets are stacked layer by layer, aligning them precisely to form
the desired geometry.
4. Cutting:
o Each layer is cut to the shape of the object using a laser or blade,
either before or after stacking.
5. Compression and Curing:
o The stack is compressed to eliminate air gaps and cured under heat
or pressure to enhance bonding.
6. Post-Processing:
o Excess material is trimmed, and the object is sanded or finished for
smoothness.
Applications:
 Furniture fabrication using wood laminates.
 Lightweight, high-strength components using fiber-reinforced laminates.
(I can provide illustrations of these processes if needed.)

PART – A
Answers:
1. Paper-Based Raw Materials in 3D Printing
Circumstances:
 Used when cost-effectiveness, sustainability, or ease of post-processing is
critical.
 Ideal for producing architectural models, prototypes, or aesthetic objects.
Example:
  Laminated Object Manufacturing (LOM) often uses paper sheets bonded
together and cut layer by layer.

2. Limitations in Materials Used in 3D Printing

 Mechanical Weakness: Many materials, such as PLA, lack sufficient strength
for functional parts.
 Limited Thermal Resistance: Plastics like ABS and PLA cannot withstand high
temperatures.
 Material Degradation: Biodegradable materials may not have the longevity
required for specific applications.
 Cost: High-performance materials, such as metals or composites, are
expensive.
 Limited Availability: Specialized materials, like bio-inks, are not widely
available.

3. Limitations of the Extrusion Process in 3D Printing

 Surface Finish: Parts often have a rough surface and visible layer lines.
 Dimensional Accuracy: Not ideal for intricate or highly precise components.
 Material Restrictions: Limited to thermoplastics and specific composites.
 Slower Speeds: Compared to other methods like SLA or SLS.
 Warping: Warping can occur due to uneven cooling of layers.

4. Types of Materials Used in Photopolymerization 3D Printing

 Standard Resins: For general-purpose printing.
 Tough Resins: For durable, impact-resistant parts.
 Flexible Resins: Mimic rubber-like properties for soft parts.
  Biocompatible Resins: Used in medical and dental applications.
 High-Temperature Resins: For heat-resistant components.

5. Applications of Biological Tissues in 3D Printing

 Tissue Engineering: Creating scaffolds for cell growth and regeneration.
 Organ Printing: Researching the production of functional organs like livers
or kidneys.
 Drug Testing: Developing tissue models to test pharmaceuticals.
 Wound Healing: Printing skin patches for burn or wound treatment.
 Dental Applications: Creating biocompatible structures for dental implants.

6. Types of Materials in 3D Printing

1. Plastics (e.g., PLA, ABS).
2. Metals (e.g., Titanium, Aluminum).
3. Ceramics (e.g., Zirconia).
4. Composites (e.g., Carbon Fiber Reinforced).
5. Biological Tissues (e.g., Collagen, Alginate-based Hydrogels).

7. Principle of Extrusion in Material Processing

Extrusion involves:
 Heating a material until it melts.
 Forcing the molten material through a nozzle.
 Depositing it in layers to form a 3D object.
This is widely used in FDM printing for its simplicity and cost-effectiveness.
8. Type of Raw Material Used in SLA Process
 Liquid Photopolymers: UV-curable resins that solidify when exposed to
specific wavelengths of light.

9. Comparison of Photopolymerization and Lamination Processes

Aspect Photopolymerization (SLA/DLP) Lamination (LOM)

Material Liquid photopolymers (resins). Paper, plastic, or metal sheets.

Lower precision, suitable for large

Accuracy High detail and precision.
parts.

Surface Rough surface, requiring post-

Smooth surface.
Finish processing.

Dental models, jewelry, and Architectural models, large-scale

Applications
prototypes. prototypes.

Expensive due to resin and Cost-effective, especially with

Cost
equipment. paper.

10. Surface Finishing Operations of 3D Printed Parts

 Sanding: Smoothens rough surfaces and layer lines.
 Polishing: Adds shine and improves surface quality.
 Chemical Treatment: Acetone vapor smoothing for ABS parts.
 Painting/Coating: Enhances aesthetics or provides additional protection.
 Machining: For precision adjustments in dimensions.