Barış Güliçli
In the simplest form we can say that 3D printing is a process of making three dimensional solid objects from a digital file. But actually 3D printing is not that simple and not that minute. Even for many it will be the cause of third industrial revolution. For instance futurologist Jeremy Rifkin is one of them. He claimed that 3D printing signals the beginning of a third industrial revolution.
HOW DOES 3D PRINTING WORK?
Modelling
It all starts with making a virtual design of the object you want to create. This virtual design is for instance a CAD (Computer Aided Design) file which is a mostly used one. This CAD file is created using a 3D modeling application or with a 3D scanner (to copy an existing object). [1.6]
When you have a 3D model, the next step is to prepare it in order to make it 3D printable.
Transforming
You will have to prepare a 3D model before it is ready to be 3D printed. This is what they call slicing. Slicing is dividing a 3D model into hundreds or thousands of horizontal layers and needs to be done with software. 3D model file such as STL which is mostly used one must be converted into something called G-code. A software called a "slicer," which converts the model into a series of thin layers also converts 3D model file to a G-code file containing instructions tailored to a specific type of 3D printer. This G-code file can then be printed with 3D printing client software which loads the G-code, and uses it to instruct the 3D printer during the 3D printing process. [1.6][1.7][1.8]
Printing
Not all 3D printers use the same technology. There are several ways to print and all those available are additive, differing mainly in the way layers are build to create the final object.
3D PRINTER TECHNOLOGIES(TYPES OF 3D PRINTERS)
Individual processes will differ depending on the material and machine technology used. Hence, in 2010, the American Society for Testing and Materials (ASTM) group “ASTM F42 – Additive Manufacturing”, formulated a set of standards that classify the range of Additive Manufacturing processes into 7 categories (Standard Terminology for Additive Manufacturing Technologies, 2012).These seven processes are:
1.Vat photopolymerisation
A 3D printer based on the Vat polymerisation uses a vat of liquid photopolymer resin, out of which the model is constructed layer by layer. An ultraviolet (UV) light is used to cure or harden the resin where required, whilst a platform moves the object being made downwards after each new layer is cured. As the process uses liquid to form objects, there is no structural support from the material during the build phase. In this case, support structures will often need to be added.[1.9]
a.Stereolithography(SLA)
The most commonly used technology in this processes is Stereolithography (SLA). Stereolithography is widely used in prototyping as it doesn’t require too much time to produce an object and cost is relatively cheap comparing to other means of prototyping. [1.10]
b.CLIP(CONTINUOUS LIQUID INTERFACE PRODUCTION)
Other technologies using Vat Photopolymerisation are the new ultrafast Continuous Liquid Interface Production or CLIP and marginally used older technologies.[1.6]
Photopolymarisation – Step by Step
1. The build platform is lowered from the top of the resin vat downwards by the layer thickness.
2. A UV light cures the resin layer by layer. The platform continues to move downwards and additional layers are built on top of the previous.
3. Some machines use a blade which moves between layers in order to provide a smooth resin base to build the next layer on.
4. After completion, the vat is drained of resin and the object removed.
2. Material jetting
In this process, material is applied in droplets through a small diameter nozzle, similar to the way a common inkjet paper printer works, but it is applied layer-by-layer to a build platform making a 3D object and then hardened by UV light as in the SLA. As material must be deposited in drops, the number of materials available to use is limited. Polymers and waxes are suitable and commonly used materials, due to their viscous nature and ability to form drops.[1.6][1.9]
3. Binder jetting
With binder jetting two materials are used: powder base material and a liquid binder. In the build chamber, powder is spread in equal layers and binder is applied through jet nozzles that “glue” the powder particles in the shape of a programmed 3D object. The finished object is “glued together” by binder remains in the container with the powder base material. After the print is finished, the remaining powder is cleaned off and used for 3D printing the next object. [1.6][1.9]
4.Material extrusion
a.Fused Deposition Modeling(FDM)
The most commonly used technology in this process is Fused Deposition Modeling (FDM). The FDM technology works using a plastic filament or metal wire which is supplying material to an extrusion nozzle which can turn the flow on and off. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism, directly controlled by a computer-aided manufacturing (CAM) software package. The object is produced by extruding melted material to form layers as the material hardens immediately after extrusion from the nozzle. This technology is most widely used with two plastic filament material types: ABS (Acrylonitrile Butadiene Styrene) and PLA (Polylactic acid). Though many other materials are available ranging in properties from wood fill to flexible and even conductive materials. The software that comes with this technology automatically generates support structures if required. The machine dispenses two materials, one for the model and one for a disposable support structure. Material is often added to the machine in spool form.[1.6][1.9]
b.Fused Filament Fabrication (FFF)
The exactly equivalent term, Fused Filament Fabrication (FFF), was given by companies who do not hold the original patents.
Material Extrusion – Step by Step
1. First layer is built as nozzle deposits material where required onto the cross sectional area of first object slice.
2. The following layers are added on top of previous layers.
3. Layers are fused together upon deposition as the material is in a melted state.
5.Powder bed fusion
Powder bed fusion (PBF) methods use either a laser or electron beam to melt and fuse material powder together. All PBF processes involve the spreading of the powder material over previous layers. There are different mechanisms to enable this, including a roller or a blade. A hopper or a reservoir below of aside the bed provides fresh material supply. [1.9]
a.Electron beam melting
EBM, methods require a vacuum but can be used with metals and alloys in the creation of functional parts. [1.9]
b.Selective Heat Sintering
SHS differs from other processes by way of using a heated thermal print head to fuse powder material together. As before, layers are added with a roller in between fusion of layers. A platform lowers the model accordingly.[1.9]
c. Selective Laser Sintering
The most commonly used technology in this processes is Selective Laser Sintering (SLS). SLS uses a high power laser to fuse small particles of plastic, metal, ceramic or glass powders into a mass that has the desired three dimensional shape. The laser selectively fuses the powdered material by scanning the cross-sections (or layers) generated by the 3D modeling program on the surface of a powder bed. After each cross-section is scanned, the powder bed is lowered by one layer thickness. Then a new layer of material is applied on top and the process is repeated until the object is completed. All untouched powder remains as it is and becomes a support structure for the object. Therefore there is no need for any support structure which is an advantage over SLA. All unused powder can be used for the next print. [1.6]
d.Direct metal laser sintering
DMLS is the same as SLS, but with the use of metals and not plastics. The process sinters the powder, layer by layer.[1.9]
Powder Bed Fusion – Step by Step
1. A layer, typically 0.1mm thick of material is spread over the build platform.
2. A laser fuses the first layer or first cross section of the model.
3. A new layer of powder is spread across the previous layer using a roller.
4. Further layers or cross sections are fused and added.
5. The process repeats until the entire model is created. Loose, unfused powder is remains in position but is removed during post processing.
6.Sheet lamination
Sheet lamination processes include ultrasonic additive manufacturing (UAM) and laminated object manufacturing (LOM).
Lamination= levha haline getirmek
a.UAM
The Ultrasonic Additive Manufacturing process uses sheets or ribbons of metal, which are bound together using ultrasonic welding. UAM uses metals and includes aluminium, copper, stainless steel and titanium. The process is low temperature and allows for internal geometries to be created. The process can bond different materials and requires relatively little energy, as the metal is not melted.[1.9]
b.LOM
Laminated object manufacturing (LOM) uses a similar layer by layer approach but uses paper as material and adhesive instead of welding. Laminated objects are often used for aesthetic and visual models and are not suitable for structural use. [1.9]
7.Directed energy deposition
Directed Energy Deposition (DED) is a more complex printing process commonly used to repair or add additional material to existing components. A typical DED machine consists of a nozzle mounted on a multi axis arm, which deposits melted material onto the specified surface, where it solidifies. The process is similar in principle to material extrusion, but the nozzle can move in multiple directions and is not fixed to a specific axis. The material, which can be deposited from any angle due to 4 and 5 axis machines, is melted upon deposition with a laser or electron beam. The process can be used with polymers, ceramics but is typically used with metals, in the form of either powder or wire.[1.9]
3D Printer Applications
A polypeptide chain model was 3D printed in such a way that it could fold into secondary structures because of the inclusion of bond rotational barriers and degrees of freedom considerations.
AVANTAGES :
The pills produced using 3D printer have a very high dissolution rate compared to normal pills.
Different ingredients can be placed in the pills according to the severity of the disease.
Special drugs of personal can be produced in this way.
BIO-PRINTED APPLICATION
General Informatian: Bio-printed tissues printed with only bio-ink. Bio-printed tissues have non-toxic effect. because bio-inks contain human stem cells and then human body can not be seen as a toxic substance to bio-printed tissue. Bio-printed tissues are experimental. because Printed tissues can not be like a complete organ. Human organs have very complex veins. This vein is not fully printed, and the printed tissue can not fulfill all functions such as real human tissue in one hundred percent.
What is the future of 3D printing technology?
1-Faster and cheaper production will exist;
We have many types of 3d printers and another types will be exist in a few years. As 2D technology this technology will be cheaper and more much faster. Today it takes hours or days for a printing it will take only seconds in the future.
2-Eatable 3D printed foods;
Today there is some examples of eatable printed foods. In the future, 3D printers will take the roll of chefs and chefs will control ingredients and design of foods. Also, we will use “3D printer chefs” in our own kitchens. [5.1][5.2]
3-4D printing technology;
4D printed materials are pre-programmed materials that can transform their shapes. Today we do 4D printings but there are no any practical applications. Imagine a scenario where you go to Ikea and buy a chair, put it in your room and it self-assembles. [5.3] [5.4]
4-3D printed artificial organ transfer;
With new methods we will able to print organ’s all details and transfer it to patients in 15 years or less. The promise of 3D printing isn’t just creating a new liver for that person who has been waiting for one for years on the national transplant list. It’s creating tailor-made organs the right size and shape for a person’s body, grown from a person’s own cells so that the body doesn’t reject it. [5.5]
5-3D printers at space;
We need to create and re-use every possible object when we are travelling or being in space. We will never have the needed time and money to transfer those objects from earth consequently if we create a base on Mars or travel on space we must use 3D printers. [5.6]
6-Changes in markets;
Markets (pharmacies, super markets, furniture markets etc.) will be 3D printable material and design providers. Imagine IKEA send you a design of furniture and sell you the materials when you print (if 4d technology developed as I said) it self-assembles. [5.7]
7- Atomic 3D printer;
Printers that uses atoms as printing materials. This will be a new generation of printing history. This will be a big revolution. Every product on earth will be cheaper and 100% recyclable.
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