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Boon to Animators: 3D Printing turns Ideas in to Reality

3D printers are like the magical portals between imagination and reality, enabling us to see our dreams come true. Especially in the creative world, 3D printing has a great role to play, as it helps the creator’s ideas to take shape. 3D printers are the best solution for creative outfits like studios, filmmakers and game designers as it offers quick and agile fabrication. The following are steps that are necessary to prepare a render/animation-ready model for 3D Printing are explained in an elaborate manner in this article. It is very necessary to follow each step very closely and carefully.

Steps for 3D printing: DIY!

Design for your material

The model does not exist in real so the material that is to be used should be chosen very carefully. The material depends on what exactly you want to print. Many people want their characters to be in color the best option for such people would be full color sandstone. Using this material enable the end user to get a model that is in color. Some people look for affordable and versatile material for proto-typing or if the design requires interlocking parts. Such people should try the strong & flexible nylon plastic. So we see as the requirement change so does the material.

Weight distribution

The distribution of weight is the most important part of 3D printing models. If the requirement is that of keeping the models standing and not falling over then make sure that the bottom of the model is strong.

Sizing is another important factor. Sizing of the model to suit your needs as well as the printer is very necessary. Based on the material the size might change during production. Some materials experience shrinkage like Brass, Bronze, Silver, and Steel.

Mesh should be water tight

A water tight mesh can be achieved by closed edges creating a solid volume. It is necessary to check the normals and make sure that they all face outwards. Any normals that are flipped will be read as holes by the printer.

Be careful of protruding appendages/ thicken vulnerable areas

There are chances that the protruding or outstretched appendages might just snap off during or after the printing is done i.e. if the point of contact or the joint to the main structure is too thin. For example if you are printing a cat, pay close attention to the vulnerable areas, such as where the cat’s tail connects to the body, the thin ears, and legs, etc.

Hollowing the model with escape holes

The price of the material depends on the material that is being used. Hollowing the model will considerably reduce the price of the model from $17 to as minimal as $3.

Separate and Interlocking Parts

3D printing allows the creation of intricate, interlocking, movable pieces without assembly. The level of intricacy and detail is unparalleled. If the finished product is to be larger than the printer bed or if a puzzle or a toy is to be made, then this can be done by printing separate parts that can interlock after printing.

Clearance

If separate or interlocking parts are to be printed then it is very important to make sure that there is sufficient distance between tight areas. Production techniques such as SLS make moving parts without assembly possible. With the help of this technology enough clearance can be created so that the models pieces do not fuse together or trap support material inside.

Remove Smoothing Modifiers

When creating organic forms in 3D modeling software, it is necessary to start with a low poly mesh for easy changes and fast building. To create this, a smoothing modifier for faster render time is to be used. 3D printers do not read smoothing modifiers so it’s necessary to modify it in the software that s being used. After this the model has a higher resolution.

Export in Readable Format for Printers

When the 3D image is ready to be printed, a readable format is needed. STL is the most common and in some cases a plugin may be needed so that the file can be exported. This totally depends on the 3D modeling software.

Print and Share

Now the sole step left is to print the model and show it off!

The process to prepare a 3D model is a bit difficult but we hope these steps shared will help you to get a better understanding 3D printing process.

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The rendezvous of the Replicators: 3D Printing Industry in China

3D Printing is a concept that is very popular and is expected to become the backbone of the manufacturing industry of major countries around the world. The 3D Printing has influenced various sectors from healthcare to jewelry industry. This 3D Printing bug bit the Chinese manufacturing market in the 2000s and the effect of this bite can be seen in China now. With the claims that are being made by many business magazines such as Economist that China is all set to become the next consumption superpower, the 3D Printing industry, which is seeing rapid strides in china, is going to play a key role.

Looking at the other world giant economies like the U.S and Europe investing huge amounts in this sector and bringing their weak and feeble manufacturing industry to a new jump start has compelled China to furiously develop its own 3D printing industry. But it will take China quite some time to pace up with the technology that already exists in U.S and other European countries; but very soon as per the claims that are being made by one of the 3D printing company in China that they have been able to make a new breed of gigantic 3D Printing that is expected to have a diameter of 1.8 meters. Another company of similar traits is betting on making a printer that is larger than the previous one.

The other significant news we heard from 3D Printing industry in China is the production of giant 3D printer by rapidly constructing 10 houses in less than 24 hours! These houses were primarily built by recycled materials and the cost was less than US$5,000. This was done so as to ease the housing crises in developing markets. With the increase in the population in China there is a need for fast and cheap housing. This dream was turned into reality by a construction firm named Winsun, which stepped forward with a very impressive demonstration of rapid construction with the help of 3D printing techniques to build 10 small houses in 24 hours. This was done in batches by Winsun’s 3D printer that created building blocks by layering up cement or glass mix in structural patterns. The diagonally reinforced print leaves plenty of air gaps to act as insulation.

The expansion of 3D printing can have a two-fold benefit for any country. The primary benefit would be at the manufacturing level, it could give Chinese companies a renewed competitive edge for domestic production. The other benefit would be at the consumption level, the boost that 3D printing gives to researching and developing new proto-types could help companies foreign as well as national to design products that are better tailored for local preferences, a boon for anyone trying to set up shop in such a large and diverse market.

The 3D printing industry is still in the growth phase in China but the government is making all the possible measures to bring the Chinese market in power with the other leading 3D printing giants. The biggest step towards this is the collaboration between China 3D printing technology industry alliance and Materialise. This is one of the most important events in the history of Chinese 3D printing industry as it marked the structural collaboration between Materialise and all the 3D printing companies in China. Materialise is one of the pioneers in the 3D printing industry and this collaboration will empower all the 3D printing industries in China with all the software and training that is necessary to raise its level in this industry.

The other important step taken in this direction is the hosting of the World 3D printing technology industry conference and exhibition. This exhibition started in 2013 and attracted 600 guests from the world of 3D printing. It was a three days event comprising of information sharing and events. But the 2014 edition of this event will feature a 3D creative competition, a 3D printing makers’ competition, a 3D printing fashion show and an elaborate exhibition of the latest 3D printing technologies, equipments and products.

Beijing Tiertime Technology, a leader in rapid prototyping and the 3D printing industry in China has made a new consumer grade 3D printer. The printer has been made for the family use, so it is a family version printer which is of the size of a coffee maker. It is available for the people at a very affordable price of 6,000 yuan which is about US$968.

As of now the commercialization of 3D printed products is taken up by select few companies in China. But this is on the verge of becoming a major segment, as some of the local enterprises are showing keen interest in the purchase of biomaterial 3D printing units. For example, a company called VisenTOP which was only supplying products to laboratories and universities, has bagged an order to produce 3D printed models commercially for the first time. EOS, a German 3D company based in China is actively promoting their technology in the Chinese market. EOS came into the Chinese market way back in 2006, but it saw marked growth over 100% only after 2011. If these are taken as indicators, we can safely predict that 3D printing industry in China is expected to flourish very soon.

The Chinese 3D market is scattered and relatively small as compared to other 3D markets all over the world. There is a shortage of a mature business models as a result businesses are unable to effectively tap into the market and also the awareness among the people about this technology is missing. As a result the 3D printing technology has not found its rightful place in the market. But with the visible changes that are there in the 3D Printing industry in China, the Chinese market too will be among the top tier nations in 3D Printing.

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3D Printing and the Big Bang Moment for the Health Care Industry

3D Printing and the Big Bang Moment for the Health Care Industry
3D Printing and Health Care Industry

There are abundant business and economic benefits of 3D Printing and Additive Manufacturing across a range of sectors. Of those sectors that is expected to benefit majorly is the medical and health care sector. The heath care sector represents one of the strongest vertical markets for industrial 3D printing (3D Printing) / additive manufacturing (AM). Whether used as supporting tools for the manufacture of personalized products or enabling supply chain compression and cost reduction, 3D Printing is the sole answer to the ever increasing demand for better healthcare facilities in the western economies as well as the developing nations.

The most exciting future opportunities of 3D Printing boom comes from the emergence of digital healthcare, wherein patients are benefiting from ultra modern scanners and diagnostic processes like CT scan , MRI scan, 3D ultra sound and intraoral laser scanning. These personalized data are providing the blue prints for the futuristic 3D printing healthcare solutions from hip and knee implants to dental crowns, from hearing aids to prosthetic limbs, orthotic footwear and prescription eye-glasses.

Here we will discuss a few of the 3D printing healthcare solutions.

The most dominant problem with men over 50years of age or of people who are above 75 years of age is joint disorders. There are various types of joint disorders and Osteoarthritis is the most common of the lot.

Arthritis is another wide spread joint disorder which has a few treatments that are available in the market to relieve the symptoms of arthritis. Since there is no known cure for this, people who suffer from severe arthritis problem in the due course of time require joint replacement.

Scientists are trying to develop a cartilage for all those suffering from these problems with the help of 3D Printing. This effort will considerably reduce the problems of millions who suffer from this chronic ailment.

The other remarkable contribution of 3D Printing is to people who are physically handicapped; especially it gives alternative options to those who were born without limbs or had lost arms or legs. The more expensive solution to this problem would be prosthetic limbs and arms. But now thanks to 3D Printing prosthetic limbs are becoming affordable and more functional than ever before.

Various organizations are mushrooming throughout the world that enables people to get on with their lives with the help of 3D Printing prosthetic limbs and arms. One of such organization is E-NABLE, which helped Jose, 53years to develop a prosthetic left hand; which he never had since he was born. Jose had used numerous prosthetic devices for many years. The prosthetics that Jose used earlier were very expensive something like $42,000 while this one was for less than $50. Same was the case with Sydney Kenadall who had lost her right arm when she was 6years in a boating accident. Her prayers were answered by three biomedical engineering students at Washington University; who found a way to 3D print prosthetic arm for as minimal as $200. Sydney and Jose; both had used prosthetic arms earlier they found the arms to be very restrictive as well very pricey as compared to their new 3D print prosthetic arms. 3D Printing arms are great relief for all those parents whose children use prosthetic arms and limbs. The price of prosthetic arms and limbs is not less for children it’s the same as that of adults. Since children grow really fast the limbs and arms too had to be modifies with time. This was a big concern for all the parents who had a budget to take care of. But not anymore; with the 3D Printing prosthetic arms and limbs; they can facilitate their children with their requirement as well as take care of their budget. This is just another feather in the cap of 3D Printing industry. There are many such people who have found an answer to their problems with the help of this machine.

The success of 3D Printing innovations do not end here, this is merely the starting! A research organization known as the Commonwealth Scientific and Industrial Research Organization (CSIRO); along with the Australian dental company known as the Oventus; have used 3D printing to make a mouthpiece for patients who are suffering from sleep apnea. Sleep apnea is a disorder in which a person can stop breathing repeatedly while sleeping. This disorder can have long term problems like heart disease, diabetes, high blood pressure and depression if proper treatment is not taken. This mouthpiece will be available for the people by 2015.

Earlier patients with sleep apnea used Continuous positive airway pressure (CPAP) machines that blew air through the nose. Other alternative was a mouthpiece that pushed the jaw forward to keep the airway open and shockwaves therapy was used to relax the nerves in the tongue. But not with the new 3D Printing mouthpieces all these problems will have one easy solution. The working of this mouthpiece is very simple. A map of the patients’ mouth is created with the help of 3D Printing scanner. This scanned image is then printed in titanium built mouthpiece that has a coating of medical grade plastic. This mouthpiece includes a duckbill that extends from the wearer’s mouth. This duckbill creates airways to allow air to flow in without any obstruction in the nose, back of the mouth, and tongue by moving through the back of the wearer’s throat.

The other significant progress made in the medical and healthcare industry is that of implants and regrowing human tissues. Very soon 3D Printing will be able to make organs and arteries for transplants. This has been possible because of Prof. Jordan Miller of the Rice University. By his method once the print button is pressed the printer builds the digital file of the organ layer by layer into a physical object, using a filament that is controlled by a small tube that is made of sugar so that in the due course of time it might dissolve. The difference between his printer and other printers is that most printers use a form of plastic rather than sugar.

But for Australians this dream is indeed on the verge of turning into reality; i.e. of being able to implant 3D printed body parts. In fact, two Australian universities are now offering masters degrees in this practice, known as bio-fabrication. For patients like Eliza Whiteside who found that she has breast cancer at the age of 28years and got both her breasts removed as a precautionary step. She tried silicon transplant but as it turn out in most cases it did not suite her and she had to get it removed. Now with this technology of 3D Printing she feels positive of getting her life back. Scientists print custom made scaffolds using bio ink and the patient’s cell to regrow human tissue. For patients like Eliza, her breast tissue would grow around the implanted scaffolds which would dissolve in the due course of time and the breasts would thrive naturally.

Similar revolutionary steps are being taken by the University of Wollongong which provides world’s first international masters in bio-fabrication. This university brings four universities which expertise in bio-fabrication. These four universities are UOW, Queensland University of Technology, Germany’s University of Wurzburg and the University Medical Centre Utrecht, in the Netherlands. These universities will admit 10students a year who will append around nine or twelve months learning abroad the intricacies of bio-fabrications. This degree is expected to open this year.

The possibilities of 3D printing are endless and the power of 3D Printing is going to open up a myriad of opportunities in the health care segment!

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Raw materials for 3D Printing

There are different technologies that are used in 3D printing and so there are various materials that are used in this process. Some printers support around 170 different types of materials for printing like PLA, ABS, Nylon, resin etc.
Materials used in 3D Printing

Unlike 2D printing, 3D printing permits its user to experiment with a wide range of materials with which dreams can turn into reality. This gives the user a complete control on the texture and strength, apart from the design. For getting a finished product it is very necessary to first construct a 3D image of the required model in the STL format, which is then sent to a 3D printer for a print out. There are four popular techniques that are used for printing your 3D models.

  • Fused Deposition Modeling
  • Stereolithography
  • Selective Laser Sintering (SLS)
  • Poly jet/ink jet 3D printing

The lesser known 3D printing technologies are:

  • Laminated object manufacturing (LOM)
  • Electron beam melting (EBM)

There are different technologies that are used in 3D printing and so there are various materials that are used in this process. Some printers support around 170 different types of materials for printing. This can broadly be categorized into four important heads.

  • Plastic
  • Powder
  • Resins
  • Other materials

Plastic:

At present the most commonly used printing technology is Fused Deposition Modeling (FDM). The FDM printers use thermoplastic filament which is heated till the melting point and then the molten plastic is placed layer by layer to form the model. These printers tend to use the following materials.

Polylactic Acid (PLA)

It is probably the easiest to work as well as environment friendly. It is basically bio degradable plastic that has been derived from sources such as corn starch and sugar canes. This is available in soft and hard grades. With the increase in the popularity of PLA, this material is expected to overtake ABS in the near future.

Polylactic acid (SOFT PLA)

It belongs to the softer version of the PLA that was discussed in the earlier point. It is rubbery and quite flexible but is available in limited colors and sources.

Acrylonitrile butadiene styrene (ABS)

It is popularly known as Lego plastic and is considered to be the best material to work with as it is strong and very safe. It is made from spaghetti like filaments. It is available in a wide range of colors and is used for making of toys, bumper stickers etc.

Polyvinyl Alcohol Plastic (PVA)

It is a type of plastic that is used as dissolvable support materials or is used for special applications. Makerbot and Shapeways are manufacturing lower-cost desktop printers like the Makerbot replicator 2; the material that these printers are using is PVA.

Polycarbonate (PC)

It requires a high temperature nozzle design and is not widely used.

Powders:

The higher end printers use powder based materials for the construction of 3D models. The various powders available by which printing can be done are:

Polyamide (Nylon)

It is a strong and flexible material that allows a high level of detailing on the model. It is commonly called as white, strong & flexible / durable plastic / white plastic. It is a very strong and highly flexible plastic that is very fine and is basically a white granular powder. Due to these characteristics it is used in the interlocking and moving parts of the model.

Alumide

It also belongs to the polymide family and has a distinct sandy and granular look. This material is very rigid and strong. The objects that are made from this material are made from a blend of gray aluminum powder and polymide; which are very fine granular powder.

Multicolor

It has a sandy and granular appearance. The objects that are made of it are made froma fine granular powder.

Resins

Resins are used in 3D printing though the freedom of designing by this material is very limited. It is a bit rigid and delicate. Liquid polymer is cured with UV light to give the end product. The typical colors of this material are white, black and transparent. There are principally three different types of resins.

High detail resins

Models that use this material are constructed from a photo polymeric liquid. This material is apt for models that require fine detailing and are small.

Paintable resin

Models that have been constructed using this material have a very smooth surface and are beautifully painted.

Transparent resin

Models are made of hardened liquid so the material is very strong, hard, stiff and water resistant by nature. This makes it an ideal material for 3D models. This material is suitable for models that require a smooth surface along with a transparent look.

Other materials:

Apart from all these materials others materials are also used for 3D printing. Such as titanium, stainless steel, bronze, brass, silver, gold, ceramics, chocolate, bio ink, bone material, Objet Digital Material, Objet Tango Family, hot glue, glass, full color sandstone and gypsum.

There are a few other materials that are still in the experimental phase and which will be a ground breaking moment if turned into reality. These materials are medication and skin.

The nature of material changes with the requirement of the model. So, there is a wide array of materials from which the most appropriate material is to be chosen.

Image Credit: Creative Tools (flickrhandle: Creative_tools)

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Expiration of Patents – A Game Changer in 3D Printing Space?

Expiration of 3D Printing Patents
Expiration of Patents – A Game Changer in 3D Printing Space?

It can be safely said that the current mad rush in 3D printing space was started in 2009 when the first of the important patents in 3D printing ie FDM got expired in 2009. With few more important patents getting closer to expiration, it is expected that the 3D printing space is going to witness phenomenal changes. Hence, it is worthwhile to look at the key patents in 3D Printing.
Fused Deposition Modelling, (FDM) Technique was patented in 1989 by by Scott Crump, co-founder of Stratasys, one of the largest manufacturers of 3D printers. This patent expired in 2009, and gave rise to a host of consumer level printers, the development of RepRap Mendel and also the founding of Makerbot.
SLS or the Selective Laser Sintering Technique was patented by Carl R. Deckard. This involves shoot powder with a laser, letting the powder melt, and put a dusting of new powder over the layer that just got created. SLS printers are basically made of two parts: a laser cutter on top, and a plunger and roller system to build up parts layer by layer below.
You can use a wide range of plastics and even metals with SLS compared to the FDM Repraps and Makerbots we have today. Laser sintering machines can print in just about any powder that melts. Everything from nylon to polycarbonate to metals are possible with laser sintering.Lasers allow for much higher accuracy than the most common 3D printers.
The reason everyone is so excited by the expiration of ‘key patents’ is the fact that other large companies besides 3D systems – Stratasys and Zcorp, for example – will be able to manufacture their own SLS printers. But even now, the bulk of professional printers produced by these companies use a method similar to SLS called polyjet, which uses an inkjet to spray binder onto powder – but this isn’t covered by the SLS patents anyway. Hence, the expiration of these key patents will only mean a reduction in cost for the very, very high end printers and may not affect the consumer level printers market much.
3D printing and rapid manufacturing is only ideal when you need to make a handful of parts. Expiration of patents is going to be an important milestone in 3D printing space, but it isn’t going to change the world overnight.

Imagesource: Opensource.com

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Latest Growth Estimates for 3D Printing Industry

Growth Estimates for 3D Printing Industry
3D Printing Industry trends

The 3D printing industry is changing the face of manufacturing process in a very rapid pace. As Goldman Sachs rightfully pointed out, 3D printing is one of the eight technologies that will creatively destroy the way business is done. The 3D printing industry is expected to go into a boom phase in a matter of few years. The profits are going to increase in leaps and bounds. Recently, three new analyst reports from reputed firms attempt to estimate the size of the fast growing sector. Significant growth in this sector is expected according to reports from firms like Lux Research, Canalys and Credit Suisse. All the three firms strongly believe that the 3D industry will become the mainstream tools in the manufacturing business and it will encounter rapid growth; the sole difference that exists in their reports would be that the growth rate; which is being predicted by all the three differently.

According to the Lux Research, the 3D printing industry will quadruple to $12 billion by the year 2025. Industries such as aerospace, medical, automotive, consumer products, architecture and electronics are considered to be the leading consumers of the 3D printing industry. The vast usage of 3D printing (3DP) in these sectors will elevate the 3D market to $12 billion by the year 2025. Lux Research says that the 3DP market growth rate will be propelled by the factors – the printer, the formulated materials and the parts that are produced. As per the estimates done by the Lux’s model; printers will be worth $3.2 billion, while $2billion represents the formulated materials and $7billion will come from the value of parts produced.

The analysts at Lux Research, which provides strategic advice and ongoing intelligence for emerging technologies, have developed a model that incorporates the industry specific materials and the requirement of the market; the adoption of new materials and the inputs that were generated by interviewing nearly 100 entities who exist in the 3D printing value chain. Based on these parameters, the Lux research team has generated some findings.

Razor Blade Model: The giants of 3D printer companies such as 3D Systems, Stratasys, and EOS sell formulated materials at a very high rate, 10 times to 100 times. This approach was acceptable as long as these companies used 3D printers for proto-typing, but it remains a major curtailing factor to the use of 3DP for production parts.

These companies want to maintain a monopoly in the market and do not allow third-party materials suppliers from entering the market.

Four companies dominate the market: The Lux innovation grid has placed only four companies in the dominant category. This is done on the basis of technical and business scores. These companies are 3D Systems, Stratasys, EOS and Arcam. When the four companies are combined the total percentage of shares that they hold in the 3DP market is 31%. Arcam is quite well known for its open materials supply model. There are a few independent material suppliers such as Raymor Industries, Taulman 3D, Made Solid and Ceralink, among them offer high potential, but none of these companies are dominant.

Expiring patents will trigger growth: In the year of 2006 many companies which had patents for 3DP technologies expired. This gave companies like Makerbot and Shapeways an opportunity to manufacture lower-cost desktop printers and consumer-facing 3DP services. A bigger change in expected in a another three years as more patents for 3DP technologies are going to expire; enabling other companies to take a plunge in the pool of 3DP. This will reduce the price of the 3DP technologies as well as widen the range of commodities available to the users.

On the other hand, Canalys estimates that the sales in the 3DP industry was $2.5bn in 2013; to which there will be a considerable growth of about $1.3bn by the year 2014, which means that the sales figure of the 3DP industry would be  $3.8bn in 2014. By the year of 2018 this figure is expected to reach $16.2bn. This represents an expected CAGR of 45.7% between 2013 and 2018.

Prediction by Canalys:

According to Canalys Senior Analyst, Tim Shepherd; “This is a market with enormous growth potential now that the main barriers to up-take are being addressed. Advances in technology are yielding faster print times and enabling objects to be printed in greater combinations of materials, colors and finishes. Crucially, prices are also falling, making the technology an increasingly feasible option for a broad variety of enterprise and consumer uses, restricted only by computer aided design competencies and printer available- both of which are set to improve significantly”.

As a short term plan, Canalys is expecting printing to order services that could bring in the considerable growth whereas on the other hand penetration of these services is lagging behind due to technological advances. The value of 3DP market is expected to grow with leap and bounds in the next few years so the value growth will reflect an increase in the commercial printer volumes and also drive growth volume and value of consumable shipments, including both resistant printing materials and removable or dissolvable support materials.

On another note, Credit Suisse holds a opinion which is slightly different from the previous two predictions. According to a Credit Suisse team led by Julian Mitchell took a plunge into this sector, and came up with some growth statistics pinpointing which market will be in the driver’s seat.

Julian Mitchell says: “Most corporate guidance defaults to the assumptions of industry consultants who estimate that the 3D printing market will grow at ~20% annually. We challenge this assumption and attempt to quantify the addressable market by investigating the opportunities within key verticals such as aerospace, automotive, health care, and consumer. We conclude that these four markets alone (which comprise ~ 50% of the AM market today) represent sufficient opportunity to sustain 20-30% annual revenue growth, bolstered by the technology’s transition from prototyping to end use parts and expansion into metals.”

The team of Credit Suisse has supported its prediction with the help of a few statistics.

The health care industry is already rolling skin deep in the 3DP industry. Mitchell and her team say that more than 90% of all hearing-aid shells today are produced through the process. There are more than 14,000 dental labs in US, and the dental industry is the principal consumer of 3DP products. The market penetration is expected to improve to 18% from 12% by 2016.

Another industry that is not untouched by the 3DP industry in the aerospace industry, Credit Suisse team sees a 30% compound annual growth rate; with airplane engines leading the way. According to the analysis that is made by the team; the capital expenditure in manufacturing an aircraft engine for example are generally 4% of sales, the majority of this is allocated in manufacturing of equipments. By 2016 the sales of the aircraft engine industry is expected to be $50bn, this in turn implies that a whole new market for printing systems for aircraft engines will be established in the year 2016 which will have a value of $1.4bn.

The most significant expansion in the 3DP will come from personal use. In the year of 2006 many companies which had patents for 3DP technologies expired. This gave companies like Makerbot which is owned by Stratasys, an opportunity to manufacture lower-cost desktop printers. Manufacturers suggest that the retail price would be in the price range of $2,200-2,800.

Image Credit: KEn Teegardin (flickrhandle: teegardin)

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What is 3D Printing

Answers for basic 3D printing questions like what is 3D Printing? When should i buy a printer etc
Frequently Asked Questions on 3D Printing

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3D printing is currently the most trending topic in the tech world. Every day, we get to read lots of news on 3D printing, 3D printers, 3D objects and so on. Many experts claim that 3D printing is a transformational technology. Harvard Business Review has even mentioned that 3D printing is going to change the world. But what exactly is 3D printing? What are its uses? How does this technology work? Very few people know answers to these questions. Common man doesn’t know this technology inspite of this technology being disruptive. This article is intended to explain about this technology in detail.

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What is 3D printing?

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In simple words, 3D printing is the process of printing a three-dimensional object from scratch. It is done by depositing material layer on layer through computer control. The digital design is fed into the 3D printer and the object is printed on the basis of the digital design by depositing material layer by layer. These objects can be of any shape, size. The fact that one can create objects directly at one’s workplace makes this technology highly disruptive and revolutionary. Please check the below video to get an understanding of the 3D printing process.

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How does 3D printing work?

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As stated above, 3D printing is the process of creating a three dimensional object by adding successive layers of material through computer controlled movement. There are various technologies that together comprise this 3D printing. But these can be broadly classified into extrusion based and powder/liquid-based. First and foremost, a 3D design has to be created. It can be achieved by scanning a 3D model or by drawing it using a various 3D modeling softwares like Maya, AutoCAD, SolidWorks, Catia, ProE.

In extrusion based 3D printing technology, the 3D printers have hot end and build plate. These two move on a three dimensional path, if extruder moves on XY axis the build plate moves on Z  axis. In some 3D printers, extruder moves only on Y axis and build plate moves on X and Z axis. A plastic filament is fed to the extruder. There the plastic melts into liquid form. That liquid gets deposited on the build plate.  The movement of the extruder, base plate is usually dictated by the design requirements. The extruder deposits material layer by layer as per the design given and accordingly the object gets created. Once the object is created, it can removed from build plate.

In powder / liquid based 3D printing; a layer of powder / liquid is spread on the build plate and a laser light is beamed on to it. The laser moves as per the design fed to the system and hits the powder / liquid at the exact locations. The point where the laser beam hits gets solidified leaving remaining part in powder form. Then one more layer of powder / liquid is spread on this first layer and the process repeats. This process continues till the object is created. Once the object is created, powder / liquid is removed to get the final object.

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What are the various technologies in 3D Printing?

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Various technologies together constitute 3D printing. Here is a brief of few famous technologies

Fused Deposition Modeling (FDM):  Fused deposition modelling (FDM) works on an “additive” principle by laying down material in layers; a plastic filament or metal wire is unwound from a coil and supplies material to produce a part. The technology was developed by S. Scott Crump in the late 1980s and was commercialized in 1990.

Stereolithography (SLA): Stereolithography is an additive manufacturing or 3D printing technology used for producing models, prototypes, patterns, and production parts up one layer at a time by curing a photo-reactive resin with a UV laser or another similar power source.

Selective Laser Sintering (SLS): Selective Laser Sintering (SLS) is an additive manufacturing technique that uses laser as power source to sinter powdered material. The laser is aimed at a particular points as defined by a 3D model and this leads to binding of the material together to create the solid structure.

Poly Jet Printing (PJP): PolyJet printing is a rapid prototyping process that uses additive manufacturing. The printers have two or more jetting heads that spray outlines of the part, layer by layer. Photopolymers are used and these get cured instantly by UV lamp within the printer creating a solid, plastic-like model that is precise and accurate. A gel like material is used as support material which is easily washed away. The model has a smooth finish and is ready for sanding, painting, drilling or tapping.

Color Jet Printing (CJP): Color jetting or binder jetting 3d printing process can produce high-definition, full-color prototypes or early-stage concept models affordably. Binder onto thin layers of powder. A roller mechanism spreads an even layer of white powder, the core material, across the build platform. The print heads then selectively jet the binder onto the powder to bind the subsequent layer of core material. The liquid binder serves the dual task of fusing the layers and coloring the part in a multitude of shades. As is the case with other powder bed systems, once a layer is completed, the powder bed drops incrementally and a roller or blade smoothens the powder over the surface of the bed, prior to the next pass of the jet heads, with the binder for the subsequent layer to be formed and fused with the previous layer.

Multi Jet Printing (MJP): MJP or MultiJet Printing is an inkjet printing process that uses piezo printhead technology to deposit either photocurable plastic resin or casting wax materials layer by layer. MJP is used to build parts, patterns and molds with fine feature detail to address a wide range of applications. These high-resolution printers are economical to own and operate and use a separate, meltable or dissolvable support material to make post-processing a breeze.

Multi Jet Fusion (MJF): Multi Jet Fusion is a powder-based technology but does not use lasers. The powder bed is heated uniformly at the outset. A fusing agent is jetted where particles need to be selectively molten, and a detailing agent is jetted around the contours to improve part resolution. While lamps pass over the surface of the powder bed, the jetted material captures the heat and helps distribute it evenly.

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What are the benefits of this technology?

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3D printing brings a host of benefits that traditional methods of manufacturing cannot.

(a) Customization: 3D printing allows for mass customization, i.e. ability to personalize products. It wasn’t possible with traditional manufacturing methods. In traditional manufacturing process, objects have to be mass produced which led to standardization. It wasn’t possible to create customized products. But with 3D printing technology, one can create personalized products.

(b) Complexity: One can build highly complex objects using 3D printing which can’t be produced using traditional manufacturing processes. This has made a significant impact on industrial applications, whereby applications are developed to materialize complex components that are proving to be both lighter and stronger than their predecessors.

(c) Tool-less: For industrial manufacturing, one of the most cost-, time- and labour-intensive stages of the product development process is the production of the tools. For low to medium volume applications, industrial 3D printing can eliminate the need for tool production and, therefore, the costs, lead times and labour associated with it. This is an extremely attractive proposition and increasing number of manufacturers are taking advantage of it. Because of the complexity advantages stated above, products and components can be designed specifically to avoid assembly requirements with intricate geometry and complex features further eliminating the labor and costs associated with assembly processes.

(d) Sustainable / Environment-Friendly: 3D printing is an energy-efficient technology that can provide environmental efficiency by utilizing up to 90% of standard materials therefore creating less waste and imposing a reduce carbon footprint compared with traditionally manufactured products.

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What are the uses of 3D Printing?

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(a) Rapid Prototyping: The primary use of 3D printing currently is for rapid prototyping of objects. Earlier companies had to spend a lot of money on prototypes but now with the help of these printers a lot of money is being saved. Prototypes made with the help of these printers are being used in many industries from sporting giants like Nike and Reebok to the medical industry from aerospace components to toys from fine arts to geospatial to architectural visualization you say it and it’s there! 3D printers are the becoming the BFFs of all!

(b) Health Care: 3D Printing is being used extensively in health care. Custom prosthetics that fit well to the patient body parts is one area where 3D printing is used. Medical scientists are also printing ear tissues, kidneys, heart using the concept called “Bio-Printing” which is still in the experimental stage. Doctors are also creating custom titanium skulls, hands, bones and so on. Also, doctors are creating 3D printed version of a patient’s body parts to study them before performing the operation.

(c) Low Volume Production:  3D printing is also extensively used in low volume production. For low volume production, tool creation is a very expensive proposition leading to increase in the price of the objects manufactured. With 3D printing, as there is no tool creation required, one can produce items in low volume and offer those at a low price without any difficulty.

(d) Fine Art: 3D printing is also extensively used in jewelry making, in creation of sculptures and in development of high value customized goods.

(e) Retail & Entertainment: 3D printing is also used in development of figurines, toys.

(f) Architectural Visualization: 3D printing is used for development of pre visualization models that can be produced quickly and inexpensively. Once these models are created, then the actual projects are built.

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Few Questions On 3D Printing?

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Can I have my own model printed?

The answer to this question is YES! You can! Now you too can have a customized model of yourself just like the Batman or Spiderman. Isn’t that interesting as well as exciting?

The perk of this printer is that once the base design is created, whether to make one copy or a thousand copies the cost per unit is the same. Due of this, there are many online vendors who are more than willing to do this for individual clients as well not worrying much about the batch size. There are few vendors who can give life to your imagination: Sculpteo, Shapeways, Ponoko, Quick Forge, i.materialise etc

Should I worry about the high costs?

The price entirely depends on the materials used and also the size of the print. Some popular vendors say that the average price on one order is somewhere in between $50 to $100.

In order to reduce the price of the model its very essential that you make sure that the 3D image that you give is proper. If not so then the model is usually printed as a solid mass rather than being hollow.

According to one of the online vendors the price of models that are solids having a dimension of 2cm x 2cm are priced at $17 whereas on the other hand models of the same dimension but which are hollow are priced at a nominal art of $3. The margin is huge! So make sure the image is upto the mark. Of course, you should not expect the cost to be as cheap as the mass produced objects. The idea of 3D printing is to make you the creator and give special attention to your requirements, at a slight premium.

Should i bother about 3D printing?

The best judge of this question would be YOU! But wouldn’t it be awesome to gift someone a 3D model of theirs and make them feel like a superhero?

Imagine you being able to hold your imagination right in your own hand! I feel that the best feeling that anyone could ever render. I think it’s worth trying at least once.

If you plan to do in a large scale for commercial purposes the odds have to be weighed but the 3D printers are the most cost effective machines when done in small quantities for exclusive design concepts.

Purchasing a personal 3D printer?

Why not? But be sure what you want to use it for. If you are a hobbyist excited about creating something on your own, you can go for the low cost DIY printers for a few hundred dollars. If you want some basic prototypes or wanting to open up a small online business, you might opt for slightly costlier models starting from US $2000. If you are very particular about your design precision or if you want more creative stuff using multi-color or multi-material technologies, then be ready to spend big bucks!

In the near future we can expect that the 3D printers will become as widely used as computers and internet. But as of now the prices are soaring for the average buyers to buy them.

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Various 3D printing technologies in India

3D printing technologies - SLA, FDM, SLS
3D printing technology, 3D printer

In the last 2-3 years, 3D printing technology has suddenly caught the fancy of any one remotely following the technology industry due to the advent of consumer level printers. But, this wonderful technology has indeed been available to the manufacturing business for the past 2 decades. Most people relate 3D printing to FDM technology, wherein the plastic material gets extruded from the nozzle and deposited layer by layer on the build plate creating a 3D dimensional object. But truth is, FDM technology evolved later and SLA is the first technology that was invented. Charles Hull invented SLA technology and went on to build 3D Systems. Overtime, many new technologies emerged into the market. In total, there are 7 well accepted technologies. These technologies together is called 3D Printing. In simple terms, 3D printing can be defined as a process that can turn print 3D models into physical objects, in different raw materials using various additive manufacturing technologies. In this article, we shall look into various 3D printing technologies that are popular in the market now:

Fused Deposition Modeling (FDM)

FDM is considered to be the most common printing method. The FDM printers use thermoplastic filament which is heated till the plastic melts and then the molten plastic is placed layer by layer to form the model. This is the most widely used technique for 3D printing because it affordable, easy to maintain, uses real engineering grade thermoplastic. The bonding force of FDM type printers isn’t very strong. This leads to layer separation of resulting prints compromising on the resolution and surface smoothness. Also, if the diameter of extruded plastic line gets smaller, the printing speed will come down drastically. FDM is popular with companies from wide range of industries – from automotive to consumer goods manufacturing. These companies mainly use this technology to built proto-types. FDM was developed by Scott Crump in the 1980’s. He was the CEO founder chairman of Stratasys Limited. Stratasys Limited is currently the leading producer of 3D printers during this decade. Most desktop level 3D printers in the market currently are FDM based 3D printers.

The video below illustrates FDM technology in detail. If you wish to watch many such videos, check out youtube channel at https://www.youtube.com/user/think3dindia

Read: Comparison of various FDM printers

Stereolithography (SLA)

The Stereolithography or the SLA is a rapid proto-typing process which makes 3D models from photo-sensitive resins or photo polymers. It uses a UV/ laser that are controlled by the computer to make a 3D model layer by layer. The best feature of SLA technology is that it is fast and accurate. The quality of finish is much better than FDM technology. Also, the finished object has better mechanical strength than FDM technology prints. The only disadvantage of SLA technology is the price. SLA printers are very expensive in the market. Benefits of SLA technology are:

• The pieces are crisp and highly detailed
• The speed of production is very high

These two factors make Stereolithography the cutting edge technology that can be applied to any industry including oil refining, petrochemical, power, marine, and municipal and medical. This technology is widely used in the jewelry business. Unlike the FDM process, in this process after the production the model needs to undergo post-curing process to impart strength to the model. This process was patented as a rapid proto-typing method in the 1980s’ by Charles Hull, who was the co founder of 3D systems, inc., a leader in the 3D printing industry.

The below video illustrates SLA technology.

 

Read: Review of Form1 SLA printer

Digital Light Processing (DLP)

Digital Light Processing (DLP) is very similar to SLA technology except that in DLP uses projector (like the kind used for office presentations or in home theaters) to cure photo polymers. It projects the image of the cross section of an object into a VAT of photopolymer. The light selectively hardens only the area specified in that image. The most recently printed layer is then repositioned to leave room for unhardened photopolymer to fill the newly created space between the print and the projector. Repeating this process builds up the object one layer at a time. DLP is known for its high resolution, typically able to reach a layer thicknesses of under 30 microns, a fraction of a sheet of copy paper.

The below video illustrates DLP technology.

Selective Laser Sintering (SLS)

This process is one of the most affordable means of making proto-types, contributing to the wide usage of this technology among the inventors, hobbyists and in different types of businesses. But on the negative side, these machines cannot be used in offices as they need special environment. Like SLA, this machine also uses high powered lasers which are potentially dangerous for office or private usage. This process is extremely beneficial for industries that require production of proto-types in a small quantity having high quality. For example: the aerospace industry for building proto-types plane parts.

This is a similar process to Stereolithography, but in SLS a computer controlled laser beam is pulsed down on a platform, that traces the cross section of objects into small particles of plastic, ceramic or glass. The laser heats the powder either below its boiling point or above the melting point so that the powder fuses together to form a solid structure. This process continues till the entire model is finished. This makes it a largely accepted process for creating proto-types as well as final products.
The process was developed and patented by Cral Deckard, an undergraduate student at university of texas and his mechanical engineer professor, Joe Beaman in the 1980s.

Below video shows SLS technology in detail

Polyjet/ Inkjet 3D printing (PJP)

Poly jet process is very similar to the ink jet printing done on paper but in this process, instead of jetting drops of ink onto paper, the printer jets layers of liquid polymer onto a tray and then the UV rays instantly cure the model. This results in the creation of a perfect proto-type. The models that are created by these printers do not require any curing time. The models can be used after the printing is done with. While printing the model the printer jets out a gel like liquid that provides strength to the model and upholds any complex geometric design on the model.

The benefits of these printers are fine detail, smooth surfaces along with speed and precision. This machine can work on a vast array of materials right from rigid opaque materials to rubber like materials to clear and translucent materials to Simulated Polypropylene and specialized photopolymers for 3D printing in the dental and medical industries.

Below video shows PolyJet technology in detail

 

Laminated object manufacturing (LOM)

Laminated object manufacturing (LOM) is a rapid prototyping (additive manufacturing) technology developed by Helisys Inc. In this technology, layers of adhesive-coated paper, plastic or metal laminates are successively glued together and cut to shape with knife or laser cutter. Objects printed with this technology can be additionally modified by machining or drilling after printing. Typical layer resolution for this process is defined by the material feedstock and usually ranges in thickness from one to a few sheets of copy paper. These printers use thousands of standard A4 sheet papers that are cut by the machine and then glued together in order to produce the finished product.

Below video shows Laminated Object Manufacturing technology in detail

Electron beam melting (EBM)

Electron beam melting (EBM) is a type of additive manufacturing for metal parts. The main difference between EBM and SLS is that EBM uses an electron beam as its power source as opposed to laser in SLS technology. EBM technology manufactures parts by melting metal powder layer by layer with an electron beam in a high vacuum. In contrast to sintering techniques, both EBM and SLM achieve full melting of the metal powder. In EBM, the final product has a higher quality and hence making it a true replacement of standard manufacturing techniques.

Below video shows Electron Beam Melting technology in detail

 

STL Format

STL is an abbreviation of the word Standard Tessellation Language(STL). 3D printers use this file format for transforming a 3D image to a 3D model. The STL file format explains the geometry of a certain image. So it becomes easier for the printer to transform the image into model. These are basically open file standards and are widely used for Computer Aided Manufacturing (CAM) or rapid proto-typing.

Image Credit: Keith Kissel (flickr handle: kakissel)

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Learning Center

MINK: This 3D Printer customizes your Makeup Kit

The world surely is becoming a more exciting place to be in, especially with a new discovery every single day. Now everything seems to be as easy as the click of a button.

With the rise of consumer level printers, the 3D printing industry is witnessing phenomenal amount of innovation. Every week, we are hearing about new applications of this awesome technology. The latest breaking news in the 3D printing industry is the invention of a new printing machine called “Mink”. The brain child behind this innovation is Grace Choi, a Harvard graduate.

Mink was first made public in the TechCrunch NY Disrupt Conference. In this conference, Grace Choi shared the concern that the make up industry charges a lot of premium from customers, for things which are basically free i.e. for the choice of different color shades. This inspired Choi to device a machine that enables the production of lipsticks or eye shadow makeup material in the color of your choice, with just one click on your computer.

Now, you might be wondering about the price for this “difficult to believe” innovation. To the surprise of most people, the printer is priced at a very low rate of $300 and the ink that is required to furnish the finished good will also be competitively priced. The colors will be abiding the standards of FDA.  The next question will obviously be about the ease of operation. The operating procedure is not very difficult, though it can get a lot of UI tweaking to make it look much easier. If there is some color that you find attractive and would love to have a lipstick of eye-shadow of the same. You just need to procure the hex code of the color. Hex codes are codes that enables the computer to identify a particular color. The next step would be just paste the code in Photoshop or paint and fill the work page with that color. Now is the most interesting part, after you hit the print button you actually find a lipstick of eye shadow of the same color in 3D!

According to Grace, the target audience of this product are  girls from the age group of 13-21, who aren’t addicted to some branded product as of now and are free to experiment. Now there arises a contradiction. Girls who can afford this printer are those who might be addicted to a brand and the ones who do not have any brand loyalty and are open to experiment may not have the buying capacity. The other problem for this printer is a bit technical. The base that is used for the production of lipstick is thicker than that used for lighter materials like eye shadow or powder. The series of stumbling blocks don’t end here. The safety and the durability of the products is also questionable. With so many uncertainties, only time can tell us whether this idea is a hit or a flop!

But if Grace can smoothen out these basic issues with Mink, the bigshots of make up industry will have a major reason to worry.

Also Read: 

Food printer is revolutionizing the way we prepare food ( Link )