How Does Technology Works

Published Date: 02 Nov 2017

ABSTRACT

The advancement in printing technology has finally evolved to an appreciable level to satisfy all the boggling minds. 3D printing is basically printing a digital file by layering solid materials in specific patterns in three dimensions. Innovative companies are trying to make these creative printers and their prints a part of your everyday life. 

3D printing is usually performed by a materials printer using digital technology. Since the start of the twenty-first century there has been a large growth in the sales of these machines, and their price has dropped substantially.

The section: How Does Technology Works? has been pen

down taking the reference from Z Corp.’s 3D PRINTERS.

KEYWORDS

Introduction

A Brief History

Main Principles

How Does Technology Works?

Printers: domestic and commercial

Applications

Real Life Applications

In Focus

Conclusion

Future Scope

References

INTRODUCTION

3D printer is unlike of the common printers. On a 3D printer the object is printed by three dimension. A 3D model is built up layer by layer. Therefore the whole process is called rapid prototyping, or 3D printing. 

A common process of rapid prototyping is to apply a fine powder (plaster, bioplastic, polyurethane, polyester, epoxy, metal, etc.) in such a 3D inkjet printers. Printer prints out the layer of powder on a bed and form a fixed object. The design is defined by a CAD file.

 Fused deposition modeling (FDM) is another method in which molten polymer is sprayed on a support layer and the model is built layer by layer. 

Another way is to use liquids, such as photopolymer, by the same inkjet-type head which is also printed each layer by layer. 

Following, an ultraviolet light is used to activate the print head so that the liquid layer becomes a solid layer. This process is also well-known as stereolithography. 

The 3D printing process starts from a number of projects from MIT in 2000. This is an extension of the rapid prototyping process where the basic concern was in a short time a prototype model to make. 

The first practical applications were in production from metallic material. 

The resolution of the current printers are among the 328 x 328 x 606 DPI (xyz) at 656 x 656 x 800 DPI (xyz) in ultra-HD resolution. The accuracy is 0.025 mm - 0.05 mm per inch. The model size is up to 737 mm x 1257 mm x 1504 mm. 

Nowadays, 3D printer is mainly used in business enterprises and concepts which demand time-saving. These include medicine, architecture but also the entertainment industry such as game and film industry. Even artists use a 3D printer for their creations in a comparatively short time in a solid shape to print. 

Today there are more and more companies that specialise in the printing of 3D models and supply services for business and individuals. 

The biggest drawback for the individual home user is still the high cost of 3D printer. Another drawback is that it takes hours or even days to print a 3D model (depending on the complexity and resolution of the model). Besides above, the professional 3D software and 3D model design is also in a high cost range. 

Alternatively there are already simplified 3D printers for hobbyist which are much cheaper. And the materials it uses is also less expensive. These 3D printers for home use are not as accurate as commercial 3D printer.

A BRIEF HISTORY

The inception of 3D printing can be traced back to 1976, when

the inkjet printer was invented. In 1984, adaptations and advances on the inkjet concept morphed the technology from printing with ink to printing with materials. In the decades since, a variety of applications of 3D printing technology have been developed across several industries. The following points brief the history of the same:

SLA was developed and patented by Dr. Carl Deckard at the University of Texas at Austin in the mid-1980s, under sponsorship of DARPA. A similar process was patented without being commercialized by R. F. Housholder in 1979.

The term "3D printing" was coined at MIT in 1995 when then graduate students Jim Bredt and Tim Anderson modified an inkjet printer to extrude a binding solution onto a bed of powder, rather than ink onto paper. The ensuing patent led to the creation of modern 3D printing companies Z Corporation (founded by Bredt and Anderson) and ExOne.

Stereolithography was patented in 1987 by Chuck Hull.

Fused deposition modelling was developed by S. Scott Crump in the late 1980s and was commercialized in 1990.

MAIN PRINCIPLES

3D Design

The use of additive manufacturing takes virtual designs from computer aided design (CAD) or animation modeling software, transforms them into thin, virtual, horizontal cross-sections and then creates successive layers until the model is complete. It is a WYSIWYG process where the virtual model and the physical model are almost identical.

The standard data interface between CAD software and the machines is the STL file format. An STL file approximates the shape of a part or assembly using triangular facets. Smaller facets produce a higher quality surface. VRML (or WRL) files are often used as input for 3D printing technologies that are able to print in full color.

Printing

To perform a print the machine reads in the design and lays down successive layers of liquid, powder, or sheet material, and in this way builds up the model from a series of cross sections. These layers, which correspond to the virtual cross section from the CAD model, are joined together or fused automatically to create the final shape. The primary advantage of additive fabrication is its ability to create almost any shape or geometric feature.

The printer resolution is given in layer thickness and X-Y resolution in dpi, or micromeres. Typical layer thickness is around 100 micromeres (0.1 mm), although some machines such as the Objet Connex series can print layers as thin as 16 micromeres. X-Y resolution is comparable to that of laser printers. The particles (3D dots) are around 50 to 100 micrometres (0.05-0.1 mm) in diameter.

Construction of a model with contemporary methods can take from several hours to several days, depending on the method used and the size and complexity of the model. Additive systems can typically produce models in a few hours, although it can vary widely depending on the type of machine being used and the size and number of models being produced simultaneously.

Traditional techniques like injection molding can be less expensive for manufacturing polymer products in high quantities, but additive fabrication can be faster, more flexible and less expensive when producing relatively small quantities of parts. 3D printers give designers and concept development teams the ability to produce parts and concept models using a desktop size printer.

Finishing

The native resolution of a printer may be sufficient for some applications; if not, resolution and surface finish can be enhanced by printing an object slightly oversized in standard resolution, then removing material with a higher-resolution subtractive process.

Some additive manufacturing techniques use two materials in the course of constructing parts. The first material is the part material and the second is the support material (to support overhanging features during construction). The support material is later removed by heat or dissolved away with a solvent or water.

HOW TECHNOLOGY WORKS?

Z Corp. 3D printers use standard inkjet printing technology to create parts layer-by-layer by depositing a liquid binder onto thin layers of powder. Instead of feeding paper under the print heads like a 2D printer, a 3D printer moves the print heads over a bed of powder upon which it prints the cross-sectional data sent from the ZPrint software. The Z Corp. system requires powder to be distributed accurately and evenly across the build platform. 3D Printers accomplish this task by using a feed piston and platform, which rises incrementally for each layer. A roller mechanism spreads powder fed from the feed piston onto the build platform; intentionally spreading approximately 30 percent of extra powder per layer to ensure a full layer of densely packed powder on the build platform. The excess powder falls down an overflow chute, into a container for reuse in the next build.

Once the layer of powder is spread, the inkjet print heads print the cross-sectional area for the first, or bottom slice of the part onto the smooth layer of powder, binding the powder together. A piston then lowers the build platform 0.1016mm (0.004"), and a new layer of powder is spread on top. The print heads apply the data for the next cross section onto the new layer, which binds itself to the previous layer. Z Print repeats this process for all of the layers of the part. The 3D printing process creates an exact physical model of the geometry represented by 3D data. Process time depends on the height of the part or parts being built. Typically, Z Corp.’s 3D printers build at a vertical rate of 25mm – 50mm (1" – 2") per hour.

When the 3D printing process completes, loose powder surrounds and supports the part in the build chamber. Users can remove the part from the build chamber after the materials have had time to set, and return unprinted, loose powder back to the feed platform for reuse. Users then use forced air to blow the excess powder off the printed part, a short process which takes less than 10 minutes. Z Corp. technology does not require the use of solid or attached supports during the printing process, and all unused material is reusable.

PRINTERS: DOMESTIC AND COMMERCIAL

There are several projects and companies making efforts to develop 3D printers suitable for desktop use at a price many households can afford, many of which are related. Much of this work was driven by and aimed at DIY/enthusiast/early adopter communities, with links to both the academic and hacker communities.

The RepRap is a one of the longest running projects in the Desktop category. The RepRap project aims to produce a free and open source software(FOSS) 3D printer, whose full specifications are released under the GNU General Public License, and which can print many of its own parts (the printed parts) to create more machines. As of November 2010, the RepRap can print plastic parts, and requires motors, electronics, and some metal support rods to be completed. Research is under way to enable the device to print circuit boards, as well as metal parts. As of 2012, several companies and individuals sell parts to build various RepRap designs, with prices starting at about €400 / US$500.

Because of the FOSS aims of RepRap, many related projects have used their design for inspiration, creating an ecosystem of many related or derivative 3D printers, most of which are also Open Source designs. The availability of these open source designs means that variants of 3D printers are easy to invent; however, the quality and complexity of various printer designs, as well as the quality of kit or finished products, varies greatly from project to project. This rapid development of open source 3D printers is gaining interest in both the developed as well as the developing world as it enables both hyper-customization and the use of designs in the public domain to fabricate open source appropriate technology through conduits such as Thingiverse. This technology can also assist in sustainable development as such technologies are easily and economically made from readily available resources by local communities to meet their needs.

The open source Fab@Home project has developed printers for general use which can use anything squirtable through a nozzle, from chocolate to silicon sealant and chemical reactants. Printers to the project's designs were available from suppliers in kit or assembled form at prices in the region of US$2000 as of 2012.

Many of these printers are available in kit form, and some are available fully assembled. The Solidoodle 2, a 6x6x6 inch printer is available fully assembled for US$499. Prices of printer kits vary from US$400 for the open source there is MeCNC H-1, US$500 for the Printrbot, both derived from previous RepRap models, to over US$2000 for the Fab@Home 2.0 two-syringe system.

Printers for commercial and domestic use

The development and hyper-customization of the RepRap-based 3D printers has produced a new category of printers suitable for both domestic and commercial use. The least expensive available machine in the assembled form is the Solidoodle 2, while the RepRapPro's Huxley DIY kit priced at around US$680 is one of the cheapest and most reliable. There are other high-end kits and fully assembled machines which are RepRap-based machines enhanced to print at high speed and high definition. Depending on application, the degree of printing resolution and speed of manufacturing lies between a personal printer and an industrial printer. A list of printers with pricing and other information is maintained. Most recently delta robots have been utilized for 3-D printing to increase fabrication speed further.

APPLICATIONS

The concept of 3D printing may sound like something out of Star Trek, but it is definitely real. Basically, it works using inkjet technology, and fine powder such as plaster, resin and cornstarch are used to build 3D models layer by layer in cross-sections. Many people across many fields of expertise have actually found practical uses for 3D printing. A few examples of these practical applications of 3D printing are as follows:

1. Engineering. Engineers always need to create prototypes of whatever products or designs they are working on. In the old days, prototypes can take weeks and a lot of manpower to create because it involves a lot of cutting and piecing together paper, wood and other materials to create the required prototype. Through 3D printing, engineers only need to make a 3D graphic image of the design they are working on and have it rendered using a 3D printer.

2. Architecture. Just like with engineers, architects need to create mockups of their designs.3D printers allow them to come up with these mockups in a short period of time and with a higher degree of accuracy. These 3D models also make it easier to visualize a design rather than just by looking at plans and drawings.

3. Advertising and marketing. Advertisers and marketers need their clients to have a more solid idea of the products they are selling. Creating 3D models of their products gives them an edge that can boost their sales.

4. Education. Learning needs to be more visual in order to become effective, especially in subjects such as chemistry, engineering, history, physics, general science, among many others. 3D printing allows teachers to create more accurate visual aids for their lessons, and these visual aids can entice students to learn more about the subject matter.

5. Medicine. There are many medical cases where surgical procedures can be a touch-and-go thing. They can be so complicated that a single error can lead to failure and loss of life for the patient. Many surgeons now use 3D renderings of the part of their patient’s body that they need to operate on to practice on the procedure they need to perform before actually performing them. It gives them more confidence and increases their chances of success in the operation.

6. Archaeology and paleontology. These two fields both deal with relics and remains that may be too delicate and valuable to handle. In order to prevent damage to these relics and remains when they are being handled or studied, 3D replicas are made instead. This also allows more scientists to study a single object at the same time.

7. Forensic pathology. Those of us who are fans of crime shows such as CSI and NCIS would know that investigating a crime scene and examining evidence can be a very complicated process. 3D printing helps a lot in such forensic investigations.

There are so many applications of 3D printing today. They may have been part of yesterday’s science fiction, but now, they are certainly part of our reality and will continue to do so into the future.

REAL LIFE APPLICATIONS

3D Printed Chairs

Freedom of Creation has produced another set of amazing furniture, this time by Dutch designer Bram Geenen. The design of the Gaudi stool and a matching chair was done mathematically, where the curves and internal structure were determined by the distribution of various forces. From design, the furniture was produced by laser sintering. These wonderful items are available now in FOC’s online shop, but they are a tad pricey: € 5854.62 (USD$7700+) for the stool alone.

3D Gem Holders

Scott Elliot of the SD300 blog came up with a great idea: print Gem holders for homemade gemstones. Well, not exactly homemade, but home-etched. You see, he happens to have a C02 laser with which he’s able to engrave tiny patterns onto the gemstones. He’s discovered the best results are obtained from engraving "lab grown rubies and sapphires (both corundum)".

Unique feature of these holders is a flexible flap on the holder’s opening, which both secures the gem for storage and allows it to be pulled out for closer inspection. A flap like this can only be printed on a Solido printer – which is sheet fed. The flap is in fact just a portion of one layer’s sheet. It may be very difficult to reproduce that design on other technologies.

Product Mockups

With mockups made on a Dimension 3D Printer, you can see your product before ever going into production

Models can be made within hours and then sanded, painted, tapped and drilled, even chrome plated, to give you a reliable representation of the actual manufactured product.

Mockups also allow you to catch design flaws and make the appropriate adjustments early and often throughout the design process.  In several instances, Dimension 3D Printers paid for themselves right away, by catching a design flaw early in the design process.

Our customers save a lot of time and money using their Dimension 3D printers for creating product mockups.

Product Cost Reduction

There are many costs involved in developing a new product. Poor communication, extensive changes and missed deadlines increase costs exponentially throughout each step of the design and development.

A recent Wohlers Industry Report notes that a modest engineering change costing $100 in the concept phase could escalate to a staggering $1,000,000 when the product is in the field.

Dimension 3D Printers allow you to reduce those costs, with better communication, collaboration and design verification throughout the process – in fact, some of our customers have claimed that their Dimension 3D Printer paid for itself in its first project alone.

IN FOCUS: UNIVERSITY OF WARWWICK

Scientists are developing new materials which could one day allow people to print out custom-designed personal electronics such as games controllers which perfectly fit their hand shape.

The University of Warwick researchers have created a simple and inexpensive conductive plastic composite that can be used to produce electronic devices using the latest generation of low-cost 3D printers designed for use by hobbyists and even in the home.

The material, nicknamed ‘carbomorph’, enables users to lay down electronic tracks and sensors as part of a 3D printed structure – allowing the printer to create touch-sensitive areas for example, which can then be connected to a simple electronic circuit board.

So far the team has used the material to print objects with embedded flex sensors or with touch-sensitive buttons such as computer game controllers or a mug which can tell how full it is.

The next step is to work on printing much more complex structures and electronic components including the wires and cables required to connect the devices to computers.

The research was led by Dr Simon Leigh in the School of Engineering at the University of Warwick.

CONCLUSION

The concept of 3D Printing is just unbelievable. With the advancements in technology their demand would increase and the prices would fall drastically. 3D Printing is a technology that is still unknown to many but for those who are familiar to it, this technology is just magical.

FUTURE SCOPE

A few decades ago, nobody ever thought that two-dimensional printing using desktop printers, let alone 3D printing, would be possible. But the impossible eventually became possible, and 3D printers are becoming part of office networks. It would not be long before these special printers would find their way into households as well and are being used by ordinary consumers. Thus 3D printers are the future delight for the upcoming generation and have very bright scope in the upcoming times.