3D Printing and Design (Advance)

UNIT-2

Syllabus

Unit-2.0 Solid based 3D Printing Processes

2.1 Basic principle and working of fused deposition modeling (FDM) process.

2.2 Liquefaction, solidification and bonding.

2.3 Laminated Object Manufacturing process.

2.4 Cost estimation of FDM 3D printed component.

Unit-2.0 Solid based 3D Printing Processes

"Solid-based" 3D printing processes generally refer to methods where solid material is
deposited layer by layer to build up an object. Unlike liquid-based processes that involve
curing or solidifying liquid resins, solid-based processes use materials in solid form, such as
powders or filaments.

2.1 Basic principle and working of fused deposition modeling (FDM) process.

Fused Deposition Modeling:

Fused Deposition Modeling (FDM) is a widely used

additive manufacturing technique that creates
three-dimensional objects by depositing material
layer by layer. Here's a detailed explanation of the
basic principle and working of the FDM process:

Basic Principle: FDM is based on the principle of extrusion, where a thermoplastic filament
is heated to its melting point and then extruded through a nozzle onto a build platform. The
material solidifies upon cooling, creating a bond between layers and forming the final 3D
object.

FDM is popular due to its simplicity, accessibility, and versatility in using a wide range of
thermoplastic materials. It's commonly used for rapid prototyping, functional parts, and
even end-use products across various industries.

Working of FDM Process: The FDM process involves several steps:

Material Preparation: The process begins with selecting the appropriate thermoplastic
filament, such as ABS, PLA, PETG, or others. The filament is wound on a spool and loaded
into the 3D printer.

1. Filament Feeding: The filament is guided from the spool to the printer's extrusion
system. The extrusion system includes a heated nozzle and a feeder mechanism that
pushes the filament forward.
2. Heating: The filament enters the heated nozzle, which is maintained at a
temperature slightly above the melting point of the filament material. As the
filament travels through the nozzle, it gradually melts, becoming a semi-liquid
material.

3. Layer Deposition: The 3D printer's control software interprets the 3D digital model
of the object and generates a set of instructions for the printer's movements. The
printer moves its nozzle along the X and Y axes, depositing melted material in precise
paths according to the design.

4. Build Platform Lowering: After one layer of material is deposited, the build platform
(or print bed) lowers slightly to accommodate the height of the new layer.

5. Cooling and Solidification: As the melted material is deposited onto the build
platform, it rapidly cools down. This cooling causes the material to solidify and
harden, forming the shape of the current layer.

6. Layer Bonding: The solidified material from the current layer bonds to the previously
deposited layers, creating a strong adhesion between layers. This layer bonding is
crucial for the structural integrity of the final object.

7. Repeat Layer Deposition: The process of layer deposition, cooling, and bonding is
repeated, building up the object layer by layer. The nozzle moves along the X and Y
axes, while the build platform lowers incrementally with each new layer.

8. Completion and Post-Processing: Once all layers are deposited, the 3D printing
process is complete. Depending on the desired finish, the printed object might
undergo post-processing steps such as support structure removal, sanding, painting,
or other finishing processes.
2.2 Liquefaction, solidification and bonding.

In Fused Deposition Modeling (FDM), three key processes occur during the 3D printing of
thermoplastic materials: liquefaction, solidification, and bonding. These processes are
crucial for the successful creation of a 3D printed object:

1. Liquefaction:

 Liquefaction is the initial step in the FDM process. It involves turning a solid
thermoplastic filament into a semi-liquid or molten state. This phase transition is
achieved by heating the filament within the printer's print head or nozzle. The
temperature at which liquefaction occurs depends on the specific thermoplastic
material being used, as different materials have different melting points. For
example, PLA filament typically melts around 180-220°C, while ABS filament melts at
approximately 230-250°C.
 Liquefaction is the process of heating the thermoplastic filament to its melting point.
This typically occurs at temperatures between 180 and 250 degrees Celsius. The
 molten filament is then deposited onto the build platform, where it cools and
solidifies.
 The liquefaction process is important for ensuring that the filament is melted evenly
and that no air bubbles are trapped. The type of filament, the temperature of the
nozzle, and the speed of the print head can all affect the liquefaction process.
 The filament is slowly fed into the heated nozzle, where it encounters the high
temperature. As it heats up, it softens and eventually becomes a viscous, semi-liquid
material ready for extrusion.

2. Solidification:

 After the thermoplastic material is extruded through the nozzle and deposited onto
the build platform or the previous layer, it begins to cool rapidly. This cooling process
is essential for solidification, during which the semi-liquid material transitions back
into a solid state. Solidification occurs when the material's temperature drops below
its melting point, causing the molecules to lose their mobility and lock into a fixed
position.
 Solidification is the process of the molten filament cooling and becoming a solid. This
is typically achieved by the heat of the nozzle and the cooling of the build platform.
 The solidification process is important for ensuring that the layers of the print are
bonded together tightly.
 The solidification process is affected by the type of filament, the temperature of the
nozzle, the speed of the print head, and the cooling of the build platform. The faster
the filament cools, the stronger the bonds between the layers will be.
 As the material solidifies, it retains the shape and geometry dictated by the 3D
model. The rapid solidification ensures that the extruded material doesn't deform or
flow after being deposited. Solidification occurs relatively quickly, especially with
small, thin layers in FDM 3D printing, which allows for precise layer-by-layer building.

3. Bonding:

 Bonding is the process by which each newly deposited layer adheres to the previous
layer or the build platform. It's the critical step that ensures the structural integrity
of the final 3D printed object. The bonding process primarily relies on the molecular
adhesion between the layers.
 Bonding is the process of the solid layers of the print adhering to each other. This is
achieved by the heat and pressure of the nozzle. The bonding process is important
for ensuring that the print is strong and durable.
 The bonding process is affected by the type of filament, the temperature of the
nozzle, the speed of the print head, and the pressure of the nozzle. The higher the
temperature of the nozzle and the pressure of the nozzle, the stronger the bonds
between the layers will be.
 As the molten material is extruded and then solidifies, it forms physical and chemical
bonds with the underlying layer. These bonds are typically strong enough to create a
cohesive structure, but they can vary in strength depending on factors like material
choice, extrusion temperature, and layer adhesion settings.
 To enhance bonding, some FDM 3D printers offer heated build platforms. Heating
the platform prevents the base layer from cooling too rapidly, which can help
improve adhesion between the first layer and the platform. Additionally, in some
cases, the use of specialized adhesion materials like adhesion sheets, rafts, or brims
can be employed to improve the bonding between the object and the build platform.
2.3 Laminated Object Manufacturing process.

Laminated Object Manufacturing (LOM) is a 3D printing process that differs significantly

from other common 3D printing technologies like Fused Deposition Modeling (FDM) or
Stereolithography (SLA). Instead of adding material layer by layer, LOM builds objects by
laminating and bonding sheets of material together.

LOM is used in applications where speed and cost-effectiveness are more important than
the highest level of detail or surface finish. It has found use in areas like rapid prototyping,
architectural modeling, and large-scale model creation where quick visualization of designs
is crucial.

Here's how the LOM process works:

1. Material Selection: LOM typically uses materials like paper, plastic film, or
composite materials as the building blocks. These materials are usually supplied in
rolls or sheets.

2. Layer Bonding: The first step in the LOM process involves bonding the individual
layers of material together. This is often done with the help of an adhesive, although
 some LOM machines may use heat or pressure to bond the layers. The adhesive is
applied only where it's needed, based on the object's digital model.

3. Cutting or Shaping: After bonding one layer, the machine uses a laser or a cutting
tool to precisely cut the desired shape of the object from the bonded sheet. This
cutting process follows the object's cross-section as defined by the 3D model.

4. Layer Stacking: Once a layer is cut, it's stacked or adhered to the previous layer. The
adhesive ensures that the layers stick together securely. This bonding and stacking
process is repeated layer by layer, with each new layer being cut and added on top
of the previous one.

5. Waste Removal: Some LOM systems create waste material as part of the cutting
process. This waste is usually removed, leaving behind only the final 3D printed
object.

6. Completion: Once all the layers have been bonded, cut, and stacked, the completed
3D printed object is typically removed from the LOM machine.

Key characteristics of the LOM process include:

 Layered Construction: LOM builds objects in a layered fashion, similar to traditional

2D printing but with the added dimension of height.

 Speed: LOM can be a relatively fast 3D printing process, especially for larger objects,
as it doesn't involve the slow, precise layer-by-layer deposition of material seen in
some other 3D printing technologies.

 Materials: LOM can use a variety of materials, including paper, plastic, or

composites. However, it may not be as versatile as some other 3D printing processes
when it comes to material selection.

 Surface Finish: The surface finish of LOM-printed objects is often textured due to the
layered nature of the process. Post-processing steps may be required to achieve a
smoother surface if desired.
2.4 Cost estimation of FDM 3D printed component.

The following are standard methods to determine the cost of your 3D printing project:

1. Specify the type of material for your 3D printer and obtain a kilogram price. Find out
its density as well.

2. Determine the model's volume for 3D printing. For greater accuracy, use your design
software.

3. Multiply the volume per material density of your model to obtain its mass.

4. Multiply the mass that was acquired by the cost of the material per kilogram. Your
3D print material cost is shown in the output. Don't forget to include labor expenses
like power and design time.

Estimating the cost of a 3D printed component using Fused Deposition Modeling (FDM)
involves considering various factors that contribute to the overall expense. The cost
estimation process can vary depending on factors such as material costs, machine time,
labor, and overheads. Here's a general approach to estimating the cost of an FDM 3D
printed component:

1. Material Cost: Calculate the cost of the thermoplastic filament used for printing. This
cost can be determined based on the price per kilogram or per spool of filament. The
amount of filament used depends on the volume and density of the object being
printed.

2. Labor Cost: Factor in the time and effort required for the operator to set up the
printer, load the filament, start the print, and potentially perform post-processing
tasks like removing support structures and cleaning the object.

3. Machine Cost: Consider the depreciation of the 3D printer over its useful life,
maintenance costs, and energy consumption. Divide the total cost over the
estimated number of prints the machine will produce during its lifetime to get a per-
print machine cost.

4. Build Time: Longer print times result in higher energy consumption and more labor
time. Estimate the time it takes to print the component, and factor in the associated
costs of labor and electricity.
 5. Support Material (if applicable): If your 3D printed component requires support
structures, factor in the cost of the additional material used and the time required to
remove these supports.

6. Waste Material: Consider any material waste generated during the printing process,
which can result from initial nozzle priming or failed prints.

7. Overheads: Include miscellaneous expenses such as facility overheads,

administrative costs, and any other indirect expenses associated with the printing
process.

8. Post-Processing Costs: If post-processing is necessary (e.g., sanding, painting,

assembly), estimate the time, labor, and materials required for these steps.

After gathering the necessary data, you can calculate the total cost using the following
formula:

Total Cost = Material Cost + Labor Cost + Machine Cost + Build Time Cost + Support Material
Cost + Waste Material Cost + Overheads + Post-Processing Costs

How Might Printing Costs be Reduced?

Machine time and material costs affect how much 3D printed components and services
charge. You should balance these aspects if you want to lower the price of 3D printing. Here
are a few practical and technical techniques to reduce the cost of 3D printing.

• Use less expensive materials.

• Pick the proper procedure.

• Reduce infill, remove support, and hollow objects to conserve printing material.

• Choose a suitable conclusion and resolution.

vivek