Bafna et al., International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974

Proceedings of BITCON-2015 Innovations For National Development National Conference on : Information Technology Empowering Digital India Review Article 3D PRINTING: ENDLESS OPPORTUNITIES 1Harsh Bafna, 2Prof. Sarang Pitale

Address for Correspondence 1Director, Ingenious Technosys, 36/B 2nd floor, New Civic Centre, Bhilai (C.G.) 2Asst. Professor, Bhilai Institute of Technology, Durg (C.G.) ABSTRACT 3D printing (or additive manufacturing, AM) is any of various processes used to make a three-dimensional object. In 3D printing, additive processes are used, in which successive layers of material are laid down under computer control. These objects can be of almost any shape or geometry, and are produced from a 3D model or other electronic data source. A 3D printer is a type of industrial robot. 3D printing in the term's original sense refers to processes that sequentially deposit material onto a powder bed with inkjet printer heads. More recently the meaning of the term has expanded to encompass a wider variety of techniques such as extrusion and sintering based processes. Technical standards generally use the term additive manufacturing for this broader sense. KEY WORDS: 3D, Printing. 1. INTRODUCTION In 1993, Massachusetts Institute of Technology 3D printing is a form of additive manufacturing (MIT) patented another technology, named "3 technology where a three dimensional object is Dimensional Printing techniques", which is similar to created by laying down successive layers of material. the inkjet technology used in 2D Printers. It is also known as rapid prototyping, is a mechanized In 1996, three major products, "Genisys" from method whereby 3D objects are quickly made on a Stratasys, "Actua 2100" from 3D Systems and reasonably sized machine connected to a computer "Z402" from Z Corporation, were introduced. containing blueprints for the object. The 3D printing In 2005, Z Corp. launched a breakthrough product, concept of custom manufacturing is exciting to nearly named Spectrum Z510, which was the first high everyone. This revolutionary method for creating 3D definition colour 3D Printer in the market. models with the use of inkjet technology saves time Another breakthrough in 3D Printing occurred in and cost by eliminating the need to design; print and 2006 with the initiation of an open source project, glue together separate model parts. Now, you can named Reprap, which was aimed at developing a create a complete model in a single process using 3D self-replicating 3D printer. printing. The basic principles include materials 3. WORKING OF A 3D PRINTER cartridges, flexibility of output, and translation of The model to be manufactured is built up a layer at a code into a visible pattern. time. A layer of powder is automatically deposited in the model tray. The print head then applies resin in the shape of the model. The layer dries solid almost immediately. The model tray then moves down the distance of a layer and another layer of power is deposited in position, in the model tray. The print head again applies resin in the shape of the model, binding it to the first layer. This sequence occurs one layer at a time until the model is complete.

Figure 1: Typical 3D Printer 3D Printers are machines that produce physical 3D models from digital data by printing layer by layer. It can make physical models of objects either designed with a CAD program or scanned with a 3D Scanner. It is used in a variety of industries including jewellery, footwear, industrial design, architecture, engineering and construction, automotive, aerospace, dental and medical industries, education and consumer products. 2. HISTORY OF 3D PRINTER The technology for printing physical 3D objects from digital data was first developed by Charles Hull in

1984. He named the technique as Stereo lithography Figure 2: Side View of Printing Process and obtained a patent for the technique in 1986. The model to be manufactured is built up a layer at a While Stereo lithography systems had become time. A layer of powder is automatically deposited in popular by the end of 1980s, other similar the model tray. The print head then applies resin in technologies such as Fused Deposition Modelling the shape of the model. The layer dries solid almost (FDM) and Selective Laser Sintering (SLS) were immediately. The model tray then moves down the introduced. Int. J. Adv. Engg. Res. Studies/IV/II/Jan.-March,2015/137-140 Bafna et al., International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974 distance of a layer and another layer of power is cross-section of the model. SHS is best for deposited in position, in the model tray. The print manufacturing inexpensive prototypes for concept head again applies resin in the shape of the model, evaluation, fit/form and functional testing. SHS is a binding it to the first layer. This sequence occurs one Plastics additive manufacturing technique similar to layer at a time until the model is complete. selective laser sintering (SLS), the main difference being that SHS employs a less intense thermal printhead instead of a laser, thereby making it a cheaper solution, and able to be scaled down to desktop sizes. 4.6 Selective Laser Melting (SLM) Selective laser melting is an additive manufacturing process that uses 3D CAD data as a digital Figure 3:A Typical 3D Printing Process Flow information source and energy in the form of a high- Chart power laser beam (usually an ytterbium fiber laser) to 4. CURRENT 3D PRINTING TECHNOLOGIES create three-dimensional metal parts by fusing fine 4.1 Stereo lithography metallic powders together. Stereo lithographic 3D printers (known as SLAs or The ASTM F42 standards committee groups stereo lithography apparatus) position a perforated selective laser melting into the category of "laser platform just below the surface of a vat of liquid sintering", although this is acknowledged as a photo curable polymer. A UV laser beam then traces misnomer because the process fully melts the metal the first slice of an object on the surface of this into a solid homogeneous mass, unlike selective laser liquid, causing a very thin layer of photopolymer to sintering (SLS) and direct metal laser sintering harden. The perforated platform is then lowered very (DMLS), which are true sintering processes. A slightly and another slice is traced out and hardened similar process is electron beam melting (EBM), by the laser. Another slice is then created, and then which, as the name suggests, uses an electron beam another, until a complete object has been printed and as the energy source. can be removed from the vat of photopolymer, 4.7 Electron Beam Melting (EBM) drained of excess liquid, and cured. Electron beam melting (EBM) is a type of additive 4.2 Fused Deposition Modelling (FDM) manufacturing (AM) for metal parts, originally Fused deposition modelling (FDM) is an additive patented and developed by Arcam. ASTM classifies manufacturing technology commonly used for EBM as a powder bed fusion technique, which also modelling, prototyping, and production applications. includes selective laser melting (SLM). The main It is one of the techniques used for 3D printing. difference is that EBM uses an electron beam as its FDM works on an "additive" principle by laying power source, as opposed to a laser. EBM technology down material in layers; a plastic filament or metal manufactures parts by melting metal powder layer by wire is unwound from a coil and supplies material to layer with an electron beam in a high vacuum. In produce a part. contrast to sintering techniques, both EBM and SLM 4.3 Selective Laser Sintering (SLS) achieve full melting of the metal powder. The term Selective Laser Sintering (SLS) is an additive selective laser sintering (SLS) is mostly historical and manufacturing technique that uses a laser as the is sometimes used to describe full melting or plastic power source to sinter powdered material (typically processes. metal), aiming the laser automatically at points in 4.8 Direct Metal Laser Sintering (DMLS) space defined by a 3D model, binding the material Direct metal laser sintering (DMLS) is an additive together to create a solid structure. It is similar to manufacturing technique that uses a laser as the direct metal laser sintering (DMLS); the two are power source to sinter powdered material (typically instantiations of the same concept but differ in metal), aiming the laser automatically at points in technical details. Selective laser melting (SLM) uses space defined by a 3D model, binding the material a comparable concept, but in SLM the material is together to create a solid structure. It is similar to fully melted rather than sintered, allowing different selective laser sintering (SLS); the two are properties (crystal structure, porosity, and so on). instantiations of the same concept but differ in SLS (as well as the other mentioned AM techniques) technical details. Selective laser melting (SLM) uses is a relatively new technology that so far has mainly a comparable concept, but in SLM the material is been used for rapid prototyping and for low-volume fully melted rather than sintered, allowing different production of component parts. Production roles are properties (crystal structure, porosity, and so on). expanding as the commercialization of AM DMLS was developed by the EOS firm of Munich, technology improves. Germany. 4.4 Multi-Jet modelling (MJM) 4.9 Laminated Object Manufacturing (LOM) This again builds up objects from successive layers Selective laser melting is an additive manufacturing of powder, with an inkjet-like print head used to process that uses 3D CAD data as a digital spray on a binder solution that glues only the required information source and energy in the form of a high- granules together. power laser beam (usually an ytterbium fibre laser) to 4.5 Selective Heat Sintering (SHS) create three-dimensional metal parts by fusing fine Selective heat sintering (SHS) is a type of additive metallic powders together. manufacturing process. It works by using a thermal The ASTM F42 standards committee groups printhead to apply heat to layers of powdered selective laser melting into the category of "laser thermoplastic. When a layer is finished, the powder sintering", although this is acknowledged as a bed moves down, and an automated roller adds a new misnomer because the process fully melts the metal layer of material which is sintered to form the next into a solid homogeneous mass, unlike selective laser Int. J. Adv. Engg. Res. Studies/IV/II/Jan.-March,2015/ Bafna et al., International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974 sintering (SLS) and direct metal laser sintering decoration of the food can be individualized based on (DMLS), which are true sintering processes. A the customer or the occasion. similar process is electron beam melting (EBM), A company called Choc Edge is currently marketing which, as the name suggests, uses an electron beam "the world's first commercial 3D chocolate printer", as the energy source. the Choc Creator. It uses a nozzle to dispense molten 4.10 Digital Light Processing (DLP) chocolate into any pattern and shape. Digital Light Processing (DLP) is a display device 5.1.2 Shelter based on of micro-electro-mechanical technology that Shelter is another basic human necessity which can uses a digital micromirror device. It was originally be an interesting application for 3D printing. The developed in 1987 by Dr. Larry Hornbeck of Texas building industry is one of the last remaining fields Instruments. While the DLP imaging device was where human labour and skills are the norm and mass invented by Texas Instruments, the first DLP based manufacturing techniques and robots are considered projector was introduced by Digital Projection Ltd in science fiction. Given that a large portion of world 1997. Digital Projection and Texas Instruments were population is without permanent shelter or food, it both awarded Emmy Awards in 1998 for the DLP would be logical to think that these basic necessities projector technology. DLP is used in a variety of should be top priority for robotized manufacturing display applications from traditional static displays to techniques yet both the construction and food interactive displays and also non-traditional industries remain labour intensive. Conventional embedded applications including medical, security, building methods are hazardous, time consuming, and industrial uses. and expensive; 3D printing of buildings can enable 4.11 Electron beam freeform fabrication (EBF3) automated creation of variety of buildings quickly Electron Beam Freeform Fabrication (EBF3) is an and efficiently. additive manufacturing process that builds complex, 5.2. Safety near-net-shape parts requiring substantially less raw Starting with base of the pyramid, primitive material and finish machining than traditional physiological human needs must be satisfied. Food manufacturing methods. It uses a focused electron and shelter are two essential needs in this group beam in a vacuum environment to create a molten which have been addressed by 3D printing research. pool on a metallic substrate. 5.2.1 Health 4.12 Robocasting While much effort is put forth by individuals, Robocasting or Direct Ink Writing (DIW) is an societies, and businesses to improve our physical additive manufacturing technique in which a filament health, an ideal health is very subjective and could of 'ink' is extruded from a nozzle, forming an object depend on location and vary over time. However, it layer by layer. The technique was first developed in can be said that the absence of sickness, specially, the United States in 1996 as a method to allow chronic illnesses is a requisite for good health. geometrically complex ceramic green bodies to be Illnesses, accidents, and aging deteriorate the body's produced by additive manufacturing. In robocasting, or a specific organ's condition. Organ transplants a 3D CAD model is divided up into layers in a have been successfully conducted for the past similar manner to other additive manufacturing century; however, there has always been a shortage techniques. A fluid (typically a ceramic slurry), of donors or an inability to find a match between the referred to as an 'ink', is then extruded through a donor and recipient in time. 3D printing is an small nozzle as the nozzle's position is controlled, advanced recent technology in this field which can be drawing out the shape of each layer of the CAD a revolutionary alternative with a variety of model. The ink exits the nozzle in a liquid-like state applications in the transplant and healthcare industry but retains its shape immediately, exploiting the in general. 3D printing research is investigated in rheological property of shear thinning. It is distinct various fields within the healthcare industry; some of from fused deposition modelling as it does not rely which are discussed in this section. on the solidification or drying to retain its shape after 5.2.1.1. Bio-Organ printing extrusion. Organ and body tissue regeneration is an incredible 5. APPLICATIONS ability observed in plants, vertebrates, and mammals. 5.1. Physiological Need However, this ability is naturally very limited in Starting with base of the pyramid, primitive humans Regenerative science is expected to provide physiological human needs must be satisfied. Food replacement tissue and entire organs by applying and shelter are two essential needs in this group tissue engineering which begins with living cells that which have been addressed by 3D printing research. are multiplied. The cells are seeded into a 3D 5.1.1 Food containment structure that facilitates the directed 3D Food is one of fundamental ingredients of life which growth and proliferation while also providing is at the base of the pyramid of human needs. nutrients to the cells. Bringing the food industry to the digital age is one of 3D printing of human tissue and organs can the essential and revolutionary applications of 3D revolutionize the healthcare industry by extending the printing. Applying this technology enables fast average life expectancy and greatly improving the automated and repeatable processes, freedom in quality of life for millions of people. Organ recipients design, as well as allowing large and easy variability will no longer have to wait months or years for a of the cooking process which can be customized for donor with the correct blood type, organ transplant each region or individual. Using robotic layer based rejection will be abolished, illegal human trafficking food printing systems allows the recipe of the food to for organ harvesting can be minimized, and war and be digitized and saved in order to prepare very accident amputees can once again gain full mobility. repeatable and high quality dishes without any 3D Bio-printing may have unprecedented margin for operator error. Also, the shape and consequences on regenerative medicine and quality

Int. J. Adv. Engg. Res. Studies/IV/II/Jan.-March,2015/ Bafna et al., International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974 of life while minimizing ethical and religious issues to automation of processes and distribution of which currently surround human embryo techniques. manufacturing needs. If the last industrial revolution 5.2.1.2. Dental implants brought us mass production and the advent of Organ and body tissue regeneration is an incredible economies of scale - the digital 3D printing ability observed in plants, vertebrates, and Dental revolution could bring mass manufacturing back a industry has been using artificial material for full circle - to an era of mass personalization, and a dentures, orthodontics, implants, crown, and bridges return to individual craftsmanship. for many years. As these parts are custom made for REFERENCES each person, the process is both time consuming and  http://en.wikipedia.org/wiki/3D_printing expensive. Direct and indirect 3D printing, namely  http://3dprinting.com/what-is-3d-printing/  http://www.inventioncity.com/intro-to-3-d- printing the actual part or a mould, has been shown to printing.html be a cheaper and faster alternative to conventional  http://www.explainingthefuture.com/3dprinting.html techniques.  http://www.mahalo.com/3d-printers/ 5.2.1.3. Skull and jaw implants  http://www.3dprinter.net/reference/what-is-3d-printing Researchers have shown that 3D printed parts can be Note: This Paper/Article is scrutinised and reviewed by Scientific Committee, BITCON-2015, BIT, Durg, CG, India used as bone replacement for people whom lost part of their skull or jaw in an accident consuming and expensive. 5.2.2 Security and integration Becoming more integrated and secured implies improving life chances and providing people with equal opportunities. These opportunities may include the ability of human communication or mobility which is considerably difficult for people with various disabilities and illnesses such as considerable in disabilities cases like Arthro-gryposis. Regarding this, 3D printing as an advanced technology can compensate the individual’s disability or deficiency by manufacturing complex composite 3D objects using 3D scanned data. It can help people regain mobility, improve their employment and social opportunities and possibly help self-reliance and alleviate self-confidence issues. 5.2. Education The education system plays an important role in aiding people achieve their full potential. 3D printing can revolutionize the learning experience by helping students interact with the subject matter. Affordable 3D printers in schools may be used for a variety of applications which can aid students in finding their field of interest easier and faster. Currently there are different types of educational projects in order to attract students to the various fields by giving them the opportunity to create and fabricate their own designs using 3D printing technology. 6. HISTORY OF 3D PRINTER 3D Printing technology could revolutionize and re- shape the world. Advances in 3D printing technology can significantly change and improve the way we manufacture products and produce goods worldwide. An object is scanned or designed with Computer Aided Design software, then sliced up into thin layers, which can then be printed out to form a solid three-dimensional product. As previously described, the importance of an invention can be appraised by determining which of the human needs it fulfills. As described, 3D printing can have an application in almost all of the categories of human needs While it may not fill an empty unloved heart, it will provide companies and individuals fast and easy manufacturing in any size or scale limited only by their imagination. One of the main advantages of the industrialization revolution was that parts could be made nearly identically which meant they could be easily replaced without individual tailoring. 3D printing, on the other hand, can enable fast, reliable, and repeatable means of producing tailor-made products which can still be made inexpensively due

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