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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-4, Apr.-2016 ADVANCED TECHNIQUES()

BALJINDER SINGH SHAHI

Master's of Technology CAD/CAM Department of Mechanical Engineering, BBSBEC Fatehgarh Sahib.

Abstract— This paper is about the advanced manufacturing technique used these days. In this paper I will explain about the history of manufacturing and computer aided designing helping increase manufacturing efficiency. This paper reports on the benefit of 3D printing, role of computer help visualize and create almost impossible designs. 3D printing is far more cost effective. Working principle of 3D manufacturing technique has been illustrated in the paper and various processes of 3D printing and the fields 3D printing is revolutionizing. Applications of 3D printing have been discussed in this paper.

Keyword— 3D printing, computer designing, revolutionizing technology, direct Ink writing

I. INTRODUCTION found at Mohen jo daro. In the year 2000 BC iron pillars, arrows hooks, nails, bowls and daggers were One of the most widely used definitions of advanced found in Delhi, Ropar, Nashik and other places. manufacturing involves the use of technology to Large scale state owned means and processes of improve products and/or processes, with the relevant metal extraction and alloying had been mentioned in technology being described as “advanced,” Kautilya’s Arthashastra dating back in the year 500 “innovative,” or “cutting edge.” For example, one BC. In 500 AD itself, cast crucible steel was first organization defines advanced manufacturing as produced in India. Probably in the year 1750 AD industries that “increasingly integrate new innovative machine tools run by the power of steam engine were technologies in both products and processes. The rate developed, that resulted in growth of production and of technology adoption and the ability to use that abundant availability of goods. During the years 1920 technology to remain competitive and add value to 1940 developments in , mass define the advanced manufacturing sector.”[1] production, interchangeable parts, die casting and lost Another author defined World Class Foundry (read wax methods, for parts required in the engineering manufacturing) as:"A World Class Manufacturing took place. While during the period of 1940 to 1960 (WCM) is one which integrates the latest-gen developments in computer manufacturing ceramic machinery with (process/ work) systems to facilitate molds, nodular irons, semi conductors and continuous 'manufacturing'- based development castings dominated the manufacturing activities. governed around manufactured [2] products only, duly During the period 1960 to 1990, in general the based over a high accent on Product Substitution or following developments took place. New Product Development." 3D technology are emerging by leaps and bounds. As 3D designing is extremely easy to understand but equally difficult to create. But with the softwares and processing power we have now a days it become easier to generate 3D models in the labs. Even one can create a 3D design at home. Its not possible to manufacture that design at home. But now its is possible with 3D printing technology aslo known as additive manufacturing.

II. HISTORY

Manufacturing activities date back to 5000 to 4000 BC. In this period the manufacturing activities were mostly oriented to wood works, stone works, metal works and earth wares. In the 2500 BC sculptures produced by lost wax casting, jewelries, earthen III. TERMINOLOGY AND METHODS wares, glass beads etcetera where recorded. During the 600 to 800 AD evidences of steel production have Early Additive Manufacturing (AM) equipment and been recorded. During the 800 to 1200 AD sand materials were developed in the 1980s.[3] In 1981, casting of cast iron was carried out. However, if we Hideo Kodama of Nagoya Municipal Industrial look at the developments in manufacturing in ancient Research Institute invented two AM fabricating India, evidences of manufacturing are available, since methods of a three-dimensional plastic model with the year 3000 BC. The earliest castings of that age photo-hardening polymer, where the UV exposure include the 11 centimeter high bronze dancing girl area is controlled by a mask pattern or the scanning

Advanced Manufacturing Techniques(3D Printing)

16 International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-4, Apr.-2016 fiber transmitter.[4][5] Then in 1984, Chuck Hull of 3D 4.2 Printing:- Before printing a 3D model from an Systems Corporation[6] developed a prototype system STL file, it must first be examined for "manifold based on a process known as stereolithography, in errors," this step being called the "fixup." Generally which layers are added by curing photopolymers with STLs that have been produced from a model obtained ultraviolet light lasers. Hull defined the process as a through 3D scanning often have many manifold "system for generating three-dimensional objects by errors in them that need to be rectified. Examples of creating a cross-sectional pattern of the object to be these errors are surfaces that do not connect, or gaps formed,"[7][8] but this had been already invented by in the models. Once that is done, the .STL file needs Kodama. Hull's contribution is the design of the STL to be processed by a piece of software called a (STereoLithography) file format widely accepted by "slicer," which converts the model into a series of 3D printing software as well as the digital slicing and thin layers and produces a G-code file containing infill strategies common to many processes today. instructions tailored to a specific type of 3D printer The term 3D printing originally referred to a process (FDM printers). This G-code file can then be printed employing standard and custom inkjet print heads. with 3D printing client software (which loads the G- The technology used by most 3D printers to date— code, and uses it to instruct the 3D printer during the especially hobbyist and consumer-oriented models— 3D printing process).Printer resolution describes layer is fused deposition modeling, a special application of thickness and X-Y resolution in dots per inch (dpi) or plastic extrusion. micrometers (µm). Typical layer thickness is around AM processes for metal sintering or melting (such as 100 µm (250 DPI), although some machines can print selective laser sintering, direct metal laser sintering, layers as thin as 16 µm (1,600 DPI).[18] X-Y and selective laser melting) usually went by their own resolution is comparable to that of laser printers. The individual names in the 1980s and 1990s. At the time, particles (3D dots) are around 50 to 100 µm (510 to nearly all metalworking was produced by casting, 250 DPI) in diameter. fabrication, stamping, and machining; although Construction of a model with contemporary methods plenty of automation was applied to those can take anywhere from several hours to several days, technologies (such as by robot welding and CNC), depending on the method used and the size and the idea of a tool or head moving through a 3D work complexity of the model. Additive systems can envelope transforming a mass of raw material into a typically reduce this time to a few hours, although it desired shape layer by layer was associated by most varies widely depending on the type of machine used people only with processes that removed metal and the size and number of models being produced (rather than adding it), such as CNC milling, CNC simultaneously. Traditional techniques like injection EDM, and many others. But AM-type sintering was molding can be less expensive for manufacturing beginning to challenge that assumption. By the mid polymer products in high quantities, but additive 1990s, new techniques for material deposition were manufacturing can be faster, more flexible and less developed at Stanford and Carnegie Mellon expensive when producing relatively small quantities University, including microcasting[9] and sprayed of parts. 3D printers give designers and concept materials.[10] Sacrificial and support materials had development teams the ability to produce parts and also become more common, enabling new object concept models using a desktop size printer. geometries.[11]

IV. WORKING PRINCIPLE

4.1 Modeling:-3D printable models may be created with a computer aided design (CAD) package, via a 3D scanner or by a plain digital camera and photogrammetry software.The manual modeling process of preparing geometric data for 3D computer graphics is similar to plastic arts such as sculpting. 3D scanning is a process of collecting digital data on the shape and appearance of a real object, creating a digital model based on it. 4.3 Finishing:-Though the printer-produced resolution is sufficient for many applications, printing a slightly oversized version of the desired object in standard resolution, and then removing material[12] with a higher-resolution subtractive process can achieve greater precision. Some printable polymers allow the surface finish to be smoothed and improved using chemical vapor processes. Some additive manufacturing techniques are capable of using multiple materials in the course of constructing parts.

Advanced Manufacturing Techniques(3D Printing)

17 International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-4, Apr.-2016 These techniques are able to print in multiple colors and color combinations simultaneously, and would not necessarily require painting. Some printing techniques require internal supports to be built for overhanging features during construction. These supports must be mechanically removed or dissolved upon completion of the print. All of the commercialized metal 3-D printers involve cutting the metal component off of the metal substrate after deposition. A new process for the GMAW 3-D printing allows for substrate surface modifications to remove aluminum[13] or steel.[14]

V. TYPES OF 3D MANUFACTURING TECHNIQUES

Several different 3D printing processes have been invented since the late 1970s. The printers were 5.1 Extrusion originally large, expensive, and highly limited in Fused deposition modeling (FDM) was developed by what they could produce. S. Scott Crump in the late 1980s and was A large number of additive processes are now commercialized in 1990 by Stratasys.[15] After the available. The main differences between processes patent on this technology expired, a large open-source are in the way layers are deposited to create parts and development community developed and both in the materials that are used. Some methods melt or commercial and DIY variants utilizing this type of 3D soften the material to produce the layers, for example. printer appeared. As a result, the price of this Selective laser melting (SLM) or direct metal laser technology has dropped by two orders of magnitude sintering (DMLS), selective laser sintering (SLS), since its creation. In fused deposition modeling the fused deposition modeling (FDM), or fused filament model or part is produced by extruding small beads of fabrication (FFF), while others cure liquid materials material which harden immediately to form layers. using different sophisticated technologies, such as stereo lithography (SLA). With laminated object manufacturing (LOM), thin layers are cut to shape and joined together (e.g. Paper, polymer, metal). Each method has its own advantages and drawbacks, which is why some companies offer a choice of powder and polymer for the material used to build the object. Others sometimes use standard, off-the-shelf business paper as the build material to produce a durable prototype. The main considerations in choosing a machine are generally speed, costs of the 3D printer, of the printed prototype, choice and cost of the materials, and color capabilities. Printers that work directly with metals are generally expensive, however, less expensive printers can be used to make a mold, which is then used to make A thermoplastic filament or metal wire that is wound metal parts on a coil is unreeled to supply material to an

Advanced Manufacturing Techniques(3D Printing)

18 International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-4, Apr.-2016 extrusion nozzle head (3D printer extruder). The Inkjet printer systems like the Objet PolyJet system nozzle head heats the material and turns the flow on spray photopolymer materials onto a build tray in and off. Typically stepper motors or servo motors are ultra-thin layers (between 16 and 30 µm) until the employed to move the extrusion head and adjust the part is completed. Each photopolymer layer is cured flow. The printer usually has 3 axes of motion. A with UV light after it is jetted, producing fully cured computer-aided manufacturing (CAM) software models that can be handled and used immediately, package is used to generate the G-Code that is sent to without post-curing. The gel-like support material, a microcontroller which controls the motors. which is designed to support complicated geometries, Extrusion in 3-D printing using material extrusion is removed by hand and water jetting. It is also involves a cold end and a hot end. suitable for elastomers. Various polymers are used, including acrylonitrile Ultra-small features can be made with the 3D micro- butadiene styrene (ABS), polycarbonate (PC), fabrication technique used in multiphoton polylactic acid (PLA), high density polyethylene photopolymerisation. This approach uses a focused (HDPE), PC/ABS, polyphenylsulfone (PPSU) and laser to trace the desired 3D object into a block of gel. high impact polystyrene (HIPS). Due to the nonlinear nature of photo excitation, the FDM is somewhat restricted in the variation of shapes gel is cured to a solid only in the places where the that may be fabricated. For example, FDM usually laser was focused while the remaining gel is then cannot produce stalactite-like structures, since they washed away. Feature sizes of under 100 nm are would be unsupported during the build. Otherwise, a easily produced, as well as complex structures with thin support must be designed into the structure moving and interlocked parts. which can be broken away during finishing. Fused deposition modeling is also referred to as fused filament fabrication (FFF) by companies who do not hold the original patents like Stratasys does.

5.2 Light Polymerized (Phtotopolymerized) Stereolithography was patented in 1986 by Chuck Hull.[16] Photopolymerization is primarily used in stereolithography (SLA) to produce a solid part from a liquid. This process was a dramatic departure from the "photosculpture" method of François Willème (1830–1905) developed in 1860 and the photopolymerization of Mitsubishi's Matsubara in 1974.[17] The "photosculpture" method consisted of photographing a subject from a variety of equidistant angles and projecting each photograph onto a screen, where a pantograph was used to trace the outline onto [18] 5.3 Powder Bed Manufacturing (Granular Binding) modeling clay In photo-polymerization, a vat of Another 3D printing approach is the selective fusing liquid polymer is exposed to controlled lighting under of materials in a granular bed. The technique fuses safelight conditions. The exposed liquid polymer parts of the layer and then moves downward in the hardens. The build plate then moves down in small working area, adding another layer of granules and increments and the liquid polymer is again exposed to repeating the process until the piece has built up. This light. The process repeats until the model has been process uses the unfused media to support overhangs built. The liquid polymer is then drained from the vat, and thin walls in the part being produced, which leaving the solid model. The EnvisionTEC Perfactory reduces the need for temporary auxiliary supports for is an example of a DLP rapid prototyping system. the piece. A laser is typically used to sinter the media into a solid. Examples include selective laser sintering (SLS), with both metals and polymers and direct metal laser sintering (DMLS).[19] Selective Laser Sintering (SLS) was developed and patented by Dr. Carl Deckard and Dr. Joseph Beaman at the University of Texas at Austin in the mid-1980s, under sponsorship of DARPA.[20] A similar process was patented without being commercialized by R. F. Housholder in 1979.[21] Selective laser melting (SLM) does not use sintering for the fusion of powder granules but will completely melt the powder using a high-energy laser to create fully dense materials in a layer-wise method that has

Advanced Manufacturing Techniques(3D Printing)

19 International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-4, Apr.-2016 mechanical properties similar to those of conventional manufactured metals. Electron beam melting (EBM) is a similar type of additive manufacturing technology for metal parts (e.g. titanium alloys). EBM manufactures parts by melting metal powder layer by layer with an electron beam in a high vacuum. Unlike metal sintering techniques that operate below melting point, EBM parts void-free.

5.5 Metal wire Processes Laser-based wirefeed systems, such as Laser Metal Deposition-wire (LMD-w), feed wire through a nozzle that is melted by a laser using inert gas shielding in either an open environment (gas surrounding the laser), or in a sealed chamber. Electron beam freeform fabrication uses an electron beam heat source inside a vacuum chamber.

Another method consists of an inkjet 3D printing system. The printer creates the model one layer at a time by spreading a layer of powder (plaster, or resins) and printing a binder in the cross-section of the part using an inkjet-like process. This is repeated until every layer has been printed. This technology VI. MANUFACTURING APPLICATIONS allows the printing of full color prototypes, overhangs, and elastomer parts. "Three-dimensional printing makes it as cheap to create single items as it is to produce thousands and 5.4 Lamination thus undermines economies of scale. It may have as In some printers, paper can be used as the build profound an impact on the world as the coming of the material, resulting in a lower cost to print. During the factory did....Just as nobody could have predicted the 1990s some companies marketed printers that cut impact of the steam engine in 1750—or the printing cross sections out of special adhesive coated paper press in 1450, or the transistor in 1950—it is using a carbon dioxide laser and then laminated them impossible to foresee the long-term impact of 3D together. In 2005 Mcor Technologies Ltd developed a printing. But the technology is coming, and it is likely different process using ordinary sheets of office to disrupt every field it touches." paper, a tungsten carbide blade to cut the shape, and selective deposition of adhesive and pressure to bond [22] 6.1 Distributed manufacturing the prototype. There are also a number of Additive manufacturing in combination with cloud companies selling printers that print laminated objects computing technologies allows decentralized and using thin plastic and metal sheets. geographically independent distributed production.[23] Distributed manufacturing as such is carried out by some enterprises; there is also a services like 3D Hubs that put people needing 3D printing in contact with owners of printers.

6.2 Mass customization Companies have created services where consumers can customize objects using simplified web based customisation software, and order the resulting items as 3D printed unique objects. [24] This now allows consumers to create custom cases for their mobile phones. Nokia has released the 3D designs for its case

Advanced Manufacturing Techniques(3D Printing)

20 International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-4, Apr.-2016 so that owners can customize their own case and have VII. INDUSTRIAL APPLICATIONS it 3D printed.[25] 7.1 Vehicle 6.3 Rapid manufacturing In early 2014, the Swedish supercar manufacturer, Rapid manufacturing is a new method of Koenigsegg, announced the One:1, a supercar that manufacturing and many of its processes remain utilizes many components that were 3D printed. In unproven. 3D printing is now entering the field of the limited run of vehicles Koenigsegg produces, the rapid manufacturing and was identified as a "next One:1 has side-mirror internals, air ducts, titanium level" technology by many experts in a 2009 exhaust components, and even complete turbocharger report.[26] One of the most promising processes looks assemblies that have been 3D printed as part of the to be the adaptation of selective laser sintering (SLS), manufacturing process.[30] or direct metal laser sintering (DMLS) some of the better-established rapid prototyping methods. As of 7.2 Construction 2006, however, these techniques were still very much The improvements in accuracy, speed and quality of in their infancy, with many obstacles to be overcome materials in 3D printing technology have opened new before RM could be considered a realistic doors for it to move beyond the use of 3-D printing in manufacturing method.[27] the modeling process and actually move it to manufacturing strategy. A good example is Dr. 6.4 Rapid prototyping Behrokh Khoshnevis’ research at the University of Industrial 3D printers have existed since the early Southern California, which resulted in a 3D printer 1980s and have been used extensively for rapid that can build a house in 24 hours .The process is prototyping and research purposes. These are called Contour Crafting generally larger machines that use proprietary powdered metals, casting media (e.g. sand), plastics, 7.3 Firearms paper or cartridges, and are used for rapid prototyping In 2012, the US-based group Defense Distributed by universities and commercial companies. disclosed plans to "[design] a working plastic gun that could be downloaded and reproduced by 6.5 Research anybody with a 3D printer." [31] Defense Distributed 3D printing can be particularly useful in research labs has also designed a 3D printable AR-15 type rifle due to its ability to make specialized, bespoke lower receiver (capable of lasting more than 650 geometries. In 2012 a proof of principle project at the rounds) and a 30 round M16 magazine The AR-15 University of Glasgow, UK, showed that it is possible has multiple receivers (both an upper and lower to use 3D printing techniques to assist in the receiver), but the legally controlled part is the one production of chemical compounds. They first printed that is serialized (the lower, in the AR-15's case). chemical reaction vessels, then used the printer to deposit reactants into them.[28] They have produced 7.4 Space new compounds to verify the validity of the process, In September 2014, SpaceX delivered the first zero- but have not pursued anything with a particular gravity 3-D printer to the International Space Station application.[28] (ISS). On December 19, 2014, NASA emailed CAD drawings for a socket wrench to astronauts aboard the 6.6 Medical Applications ISS, who then printed the tool using its 3-D printer. Professor Leroy Cronin of Glasgow University Applications for space offer the ability to print parts proposed in a 2012 TED Talk that it was possible to or tools on-site, as opposed to using rockets to bring use chemical inks to print medicine.[29] Similarly, 3D along pre-manufactured items for space missions to printing has been considered as a method of human colonies on the moon, Mars, or elsewhere.[32] implanting stem cells capable of generating new The European Space Agency plans to deliver its new tissues and organs in living humans.[29] Portable On-Board 3D Printer (POP3D for short) to the International Space Station by June 2015, making it the second 3D printer in space.[32]

7.5 Education and research 3D printing, and open source RepRap 3D printers in particular, are the latest technology making inroads into the classroom.[33] 3D printing allows students to create prototypes of items without the use of expensive tooling required in subtractive methods. Students design and produce actual models they can hold. The classroom environment allows students to learn and employ new applications for 3D printing.[33]

Advanced Manufacturing Techniques(3D Printing)

21 International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-4, Apr.-2016 RepRaps, for example, have already been used for an [11] Prinz, F. B.; Merz, R.; Weiss, Lee (1997). Ikawa, N., ed. educational mobile robotics platform.[33] Building Parts You Could Not Build Before. Proceedings of the 8th International Conference on Production Engineering. 2-6 Boundary Row, London SE1 8HN, UK: 7.6 Environmental use Chapman & Hall. pp. 40–44. In Bahrain, large-scale 3D printing using a sandstone- [12] Frick, Lindsey. http://machinedesign.com/3D- like material has been used to create the unique coral- printing/how-smooth-3D-printed-parts [13] Amberlee S. Haselhuhn, Eli J. Gooding, Alexandra G. shaped structures, which encourage coral polyps to Glover, Gerald C. Anzalone, Bas Wijnen, Paul G. Sanders, colonize and regenerate damaged reefs. These Joshua M. Pearce. (2014). "Substrate Release Mechanisms structures have a much more natural shape than other for Gas Metal Arc 3-D Aluminum Metal Printing.". 3D structures used to create artificial reefs, and, unlike Printing and Additive Manufacturing 1 (4): 204–209. doi:10.1089/3Dp.2014.0015. concrete, are neither acid nor alkaline with neutral [14] Amberlee S. Haselhuhn, Bas Wijnen, Gerald C. Anzalone, [34] pH. Paul G. Sanders, Joshua M. Pearce, In Situ Formation of Substrate Release Mechanisms for Gas Metal Arc Weld CONCLUSION Metal 3-D Printing. Journal of Materials Processing Technology. 226, pp. 50–59 (2015) DOI: 10.1016/j.jmatprotec.2015.06.038 Additive manufacturing, starting with today's infancy 10.1016/j.jmatprotec.2015.06.038 period, requires manufacturing firms to be flexible, [15] Chee Kai Chua; Kah Fai Leong; Chu Sing Lim (2003). ever-improving users of all available technologies to Rapid Prototyping. World Scientific. p. 124. ISBN 978- 981-238-117-0. remain competitive. Advocates of additive [16] U.S. Patent 4,575,330 manufacturing also predict that this arc of [17] NSF JTEC/WTEC Panel Report-RPA technological development will counter globalization, [18] Beaumont Newhall (May 1958) "Photosculpture," Image, as end users will do much of their own manufacturing 7 (5) : 100–105 François Willème, "Photo-sculpture," U.S. Patent no. 43,822 (August 9, 1864). Available on-line rather than engage in trade to buy products from other at: U.S. Patent 43,822 François Willème (May 15, 1861) people and corporations. The real integration of the "La sculpture photographique", Le Moniteur de la new additive technologies into commercial photographie, p. 34 production, however, is more a matter of [19] Frick, Lindsey. Aluminum-powder DMLS-printed part finishes race first. Machine Design Magazine, 3 March complementing traditional subtractive methods rather 2014 [36] than displacing them entirely. 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