3D Printing E-Book

Mercury Learning and Information

• Herausgeber: Packt Publishing
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 449

Veröffentlichungsjahr: 2024

Beschreibung

This book offers a comprehensive introduction to the field of 3D printing, covering its applications in industry, education, and the DIY community. It delves into common 3D printers, materials, and software, guiding you through setting up your own printer and performing essential calibration tasks. Through full-color images, you’ll learn about various printing methods, best practices, and how to finish your projects successfully.
The book is divided into three parts: the first part provides a history and evolution of 3D printers, highlighting their industrial and personal use. The second part walks you through setting up a 3D printer, from initial hardware calibration to software functionalities and acquiring 3D objects. You’ll also find step-by-step guides for three different projects.
The final part helps you choose the right printer, explains common features, and explores post-market modifications. Understanding 3D printing is crucial as it revolutionizes manufacturing and prototyping processes, enabling creativity and innovation in various fields. This book ensures a smooth journey from a novice to a confident 3D printing enthusiast, equipped with practical skills and knowledge. Companion files with videos, printable objects, and additional lessons enhance your learning experience.

Leseprobe

3D PRINTING

LICENSE, DISCLAIMER OF LIABILITY, AND LIMITED WARRANTY

By purchasing or using this book (the “Work”), you agree that this license grants permission to use the contents contained herein, but does not give you the right of ownership to any of the textual content in the book or ownership to any of the information or products contained in it. This license does not permit uploading of the Work onto the Internet or on a network (of any kind) without the written consent of the Publisher. Duplication or dissemination of any text, code, simulations, images, etc. contained herein is limited to and subject to licensing terms for the respective products, and permission must be obtained from the Publisher or the owner of the content, etc., in order to reproduce or network any portion of the textual material (in any media) that is contained in the Work.

MERCURY LEARNING AND INFORMATION (“MLI” or “the Publisher”) and anyone involved in the creation, writing, or production of the companion disc, accompanying algorithms, code, or computer programs (“the software”), and any accompanying Web site or software of the Work, cannot and do not warrant the performance or results that might be obtained by using the contents of the Work. The author, developers, and the Publisher have used their best efforts to insure the accuracy and functionality of the textual material and/or programs contained in this package; we, however, make no warranty of any kind, express or implied, regarding the performance of these contents or programs. The Work is sold “as is” without warranty (except for defective materials used in manufacturing the book or due to faulty workmanship).

The author, developers, and the publisher of any accompanying content, and anyone involved in the composition, production, and manufacturing of this work will not be liable for damages of any kind arising out of the use of (or the inability to use) the algorithms, source code, computer programs, or textual material contained in this publication. This includes, but is not limited to, loss of revenue or profit, or other incidental, physical, or consequential damages arising out of the use of this Work.

The sole remedy in the event of a claim of any kind is expressly limited to replacement of the book, and only at the discretion of the Publisher. The use of “implied warranty” and certain “exclusions” vary from state to state, and might not apply to the purchaser of this product.

Companion files for this book may be downloaded from the publisher by writing to [email protected].

3D PRINTING

AN INTRODUCTION

Stephanie Torta

Jonathan Torta

MERCURY LEARNING AND INFORMATION

Dulles, Virginia

Boston, Massachusetts

Copyright ©2019 by MERCURY LEARNING AND INFORMATION. All rights reserved.

This publication, portions of it, or any accompanying software may not be reproduced in any way, stored in a retrieval system of any type, or transmitted by any means, media, electronic display or mechanical display, including, but not limited to, photocopy, recording, Internet postings, or scanning, without prior permission in writing from the publisher.

Publisher: David Pallai

MERCURY LEARNING AND INFORMATION

22841 Quicksilver Drive

Dulles, VA 20166

[email protected]

www.merclearning.com

[phone]

This book is printed on acid-free paper in the United States of America.

S. Torta and J. Torta. 3D Printing: An Introduction

ISBN-13: 978-1683922094

The publisher recognizes and respects all marks used by companies, manufacturers, and developers as a means to distinguish their products. All brand names and product names mentioned in this book are trademarks or service marks of their respective companies. Any omission or misuse (of any kind) of service marks or trademarks, etc. is not an attempt to infringe on the property of others.

Library of Congress Control Number: 2019901183

Our titles are available for adoption, license, or bulk purchase by institutions, corporations, etc. For additional information, please contact the Customer Service Dept. at [phone] (toll free). Digital versions of our titles are available at: www.academiccourseware.com and other e-vendors. Companion files for this title may be requested at [email protected].

The sole obligation of MERCURY LEARNING AND INFORMATION to the purchaser is to replace the disc, based on defective materials or faulty workmanship, but not based on the operation or functionality of the product.

Stephanie Torta

There were many people who helped with the making of 3D Printing: An Introduction. Although there are too many to name, I would like to mention a few whose support went above and beyond. First, I would like to say a big, “Thank you,” to my brother who is an incredible coauthor. His eagerness to learn, intelligences, and willingness to pass on that knowledge have always inspired me. Writing this book together only increased that feeling. It was a privilege and an honor to work together on this book with him. Thank you to Cara who really should be listed as a coauthor for all her incredible help in bringing this book together. Thank you to Eric, Michelle, Kristin, Kristen, Rachel, Dave, and Colleen for their friendship and insight in the publishing world. To all my friends who gave us their support and let me talk endlessly about the book. To everyone who took the time to share their knowledge with quotes and interviews for the book. And most of all, I would like to give thanks to my mother; without her support this book would not have been possible. Thank you!

Jonathan Torta

An amazing thank you to all who made this book a reality. I never knew how much went into a book and now I do. To my sister and her patience who was the main mover of this entire enterprise going far beyond author and touching every aspect of this book and had to deal with me learning on the fly. To my wife Cara and mother Diana who corrected the many typographical mistakes and wrangled the words far beyond my own capability and much more. To my good friends Jen, Dave, and Dale that not only gave me support but also interesting projects and stories to add to this book. They keep me on my toes and push my limits with their interesting ideas and projects. And to Eric and other fellow 3D printers who were kind enough to give us insights on how they use these amazing devices in their businesses and also shared their stories. This book was a much larger project then I ever thought it would be and it required all to complete it. Thank you!

Acknowledgments

Introduction

Part 1 – An Overview of 3D Printing

CH1 – A Brief Overview of 3D Printing

1.1 – What is 3D Printing?

1.2 – What are the steps of the printing process?

1.3 – What are some common parts used in a desktop 3D printer?

1.4 – How was the technology for 3D Printers invented and first used?

1.5 – What is the potential for 3D printers?

Summary

Applying What You’ve Learned

CH2 – 3D Printer Use in Industry

2.1 – How are 3D printers being used in industry?

2.2 – What is the potential growth of 3D printer use in industry?

Summary

Applying What You’ve Learned

CH3 – 3D Printers and Education

3.1 – How are 3D printers affecting learning in education centers and libraries?

3.2 – What is self-guided learning?

Summary

Applying What You’ve Learned

CH4 – Do-It-Yourself 3D Printing

4.1 – When should I use additive manufacturing for my DIY projects?

4.2 – How are entrepreneurs using 3D printers?

4.3 - What can hobbyists use 3D printers for?

Summary

Applying What You’ve Learned

CH5 – Types of 3D Printers

5.1 – What are some types of 3D printers?

5.2 – What are some industrial additive manufacturing methods?

5.3 – Are there common desktop or DIY printers?

5.4 – How does an FDM 3D printer work?

5.5 – What are some FDM printer components?

Summary

Applying What You’ve Learned

CH6 – Printable Materials including FDM Filament

6.1 – What are some materials 3D printers can use?

6.2 – How do I select the materials to use for my FDM printer?

6.3 – What are some common basic filament for FDM printers?

6.4 – Are there hybrid materials?

6.5 – What specialty materials can I print with my FDM printer?

Summary

Applying What You’ve Learned

CH7 – Applications and Slicing Settings

7.1 – What types of applications are used for 3D printing?

7.2 – What software can I use to create a 3D model?

7.3 – What are some slicing applications?

7.4 – What are some common basic slicer settings?

7.5 – What are some common advanced slicer settings?

7.6 – Are there additional software applications used in 3D printing?

Summary

Applying What You’ve Learned

CH8 – Getting Started

8.1 – How do I obtain a 3D Model?

8.2 – What are some of the differences between file formats?

8.3 – How do I condition or repair a 3D Model for slicing?

8.4 – When do I slice my 3D model?

8.5 – Should I use a 3D printing service?

8.6 – What do I look for in a printer?

Summary

Applying What You’ve Learned

CH9 – Setting Up to Print

9.1 – How do I slice my 3D model?

9.2 – Do I have to worry about safety and ventilation?

9.3 – Why do I need to run hardware tests?

9.4 – How can I transfer my file to my printer?

9.5 – What happens during a print? Is there anything I need to watch out for?

9.6 – Are there ways to remotely monitor my printer?

Summary

Applying What You’ve Learned

Part 2 – Using your 3D Printer

CH10 – Calibration

10.1 – What is the importance of calibrating my printer?

10.2 – The calibration project Mow CAL

10.3 – Where can I go for troubleshooting help?

Summary

Applying What You’ve Learned

CH11 – Buying and Calibrating Your Filament

11.1 – A quick guide to picking filament

11.2 – Now that you have filament, what is next?

11.3 – Why is printing a benchmark slug important?

Summary

Applying What You’ve Learned

CH12 – Challenges

12.1 – My printer is calibrated and I made the benchmark slug – what’s next?

12.2 – What are some potential issues?

12.3 – The challenges!

Summary

Applying What You’ve Learned

CH13 – Refining and Finishing the Print

13.1 – How can I refine and finish my print?

13.2 – What are some tools I can use?

13.3 – Are there safety and ventilation concerns?

13.4 – What are some common practical refinement steps?

13.5 – How can I clean my print?

13.6 – How can I refine the surface?

13.7 – How do I paint my print?

13.8 – Additional techniques

Summary

Applying What You’ve Learned

Part 3 – Knowledge Base

CH 14 – Buying and Modifying Your Printer

14.1 – Background

14.2 – What modifications can I make to my printer?

Summary

Applying What You’ve Learned

CH15 –Maker Minds

15.1 – Collaborating with the maker community

15.2 – The maker community

Summary

Applying What You’ve Learned

Appendices

A – Extras

B – Glossary

Index

Introduction from the Maker

I have been 3D printing for just under 10 years, starting from a kit and moving to quite a few other printers along the way, always learning more and modifying them along the way. Being a tinkerer, hobbyist and DIYer, 3D printing was a perfect match, allowing me to make useful parts and also being a hobby all in its own right. I am always learning more, but I’ve found that others have been coming to me for help and advice, and that my experience was valuable to the community. So, I helped out where I could on various forums and enthusiast groups. In making this book, I’m hoping to help many more people by gathering often repeated tips in a single place. In this process I also learned quite a bit in the 3D printing, authoring and bookmaking realms. I very much hope everyone that reads this book can find something useful and helpful.

What this book is trying to achieve

3D Printing: An Introduction is intended to give aspiring makers a realistic look at the overall 3D printing process. Many books have been written about select aspects of 3D printing, this book tries gives the maker a true understanding of what it is actually like to work on a project, whether it be by using a 3D printing service or using their own printer. And to help new makers navigate potential pitfalls when printing.

What this book entails

The first part of 3D Printing: An Introduction focuses on an overview of the 3D printing process and how it fits into our lives. What types of printers, services, materials, and software is available

The second part of this book is more focused learning. It shows the first steps and what to think about when setting-up and calibrating your printer for your first print. We also gave some practice challenges and information on finishing and refinement.

The third part of the book expands on the basic printer as well as resources to increase your knowledgebase.

In addition, we have provided a DVD and a site for online download that includes a number of additional videos, images, a quick reference print checklist, a useful link guide, and practice files. We also included a few additional learning challenges and exercises for further study. The print checklist is useful to post near your printer for a quick reference guide. The companion files on the disc may be downloaded by writing to the publisher at [email protected].

All images are copyright by Jonathan or Stephanie Torta unless otherwise noted.

Part 01:

By ssp48 - 3d-printer-for-plastic-L4K3BJW - Envato Elements:

https://elements.envato.com/

Chapter 01:

By ssp48 - 3d-printer-for-plastic-PNLVJNN - Envato Elements:

https://elements.envato.com/

Figure 1.1:

By Svitlana Lozova [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], from Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:3D_printing_functional_prototypes.jpg

Figure 1.2:

By Jonathan Juursema [CC BY-SA 3.0 (

https://creativecommons.org/licenses/by-sa/3.0

)], from Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:Felix_3D_Printer_-_Printing_Head_Cropped.JPG

Figure 1.3:

By Creative Tools from Halmdstad, Sweden [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:3D-print_of_a_spool_holder_on_a_ Printrbot_Simple_Metal_3D-printer_(15646389161).jpg

Figure 1.4:

By Maurizio Pesce from Milan, Italia (Ultimaker 3D Printer) [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:Ultimaker_3D_Printer_(16862205332).jpg

Figure 1.6:

By Kaboldy [CC BY-SA 3.0 (

https://creativecommons.org/licenses/by-sa/3.0

)], from Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:STL_ sample_2.png

Figure 1.8:

By PranjalSingh IITDelhi [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], from Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:Supports_in_3D_printing.png

Figure 1.9:

By Jonathan Juursema [CC BY-SA 3.0 (

https://creativecommons.org/licenses/by-sa/3.0

)], from Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:Felix_3D_Printer_-_Printing_Set-up_With_Examples.JPG

Figure 1.10:

By John Abella from Outside Philadelphia, USA (Make Magazine 3D Printer Shootout) [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:3D_print_in_ process_(9437659715).jpg

Figure 1.11:

Mos.ru [CC BY 4.0 (

https://creativecommons.org/licenses/by/4.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:3D_printed_ tactile_replica_of_the_Tsar_Cannon.jpg

Figure 1.13:

By monkeybusiness - female-college-student-printing-3d-object-in-PJDXM2Z -Envato Elements:

https://elements.envato.com/

Chapter 02:

By ssp48 - 3d-printer-for-plastic-4QR9WVP - Envato Elements:

https://elements.envato.com/

Figure 2.1:

By Intel Free Press [CC BY-SA 2.0 (

https://creativecommons.org/licenses/by-sa/2.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:Mojo_3D_Printer.png

Figure 2.1:

NASA/MSFC/David Olive. -

https://www.nasa.gov/centers/marshall/news/nasa-advances-additive-manufacturing-for-rocket-propulsion.html

Figure 2.3:

NASA/Glenn Benson. -

https://images.nasa.gov/details-KSC-20180316-PH_ GEB01_0132.html

Figure 2.4 –

By Creative Tools from Halmdstad, Sweden [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:VIUscan_handheld_3D_scanner_in_use.jpg

Figure 2.5 –

By Ryan Somma from Occoquan, USA (Fossils and Foam) [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:3D_printed_Spinosaurus_skulls.jpg

Figure 2.6 –

By Svitlana Lozova [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], from Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:Architectural_model_printed_with_an_Ultimaker_3D_printer.jpg

Figure 2.7 –

By Marczoutendijk [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], from Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:3D_printed_concrete_bicycle_bridge_in_Gemert_(NL).jpg

Figure 2.8 –

By 3DPrinthuset (Denmark) [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:The_3D_construction_printer_constructing_The_BOD.jpg

Figure 2.9:

By 3DPrinthuset (Denmark) [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:The_building_on_demand_(BOD)_printer.jpg

Figure 2.10:

By 3DPrinthuset (Denmark) [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:The_BOD_-_3D_printed_walls_of_the_structure.jpg

Figure 2.11:

By 3DPrinthuset (Denmark) [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:The_BOD_ _Europe%27s_first_3D_printed_building.jpg

Figure 2.12-15:

Use with permission from Natural Machines:

https://www. naturalmachines.com/

Figure 2.16:

A. Envato Elements: broccoli-PPDA48C -

https://elements.envato.com/-sabinoparente

B. Use with permission from Natural Machines:

https://www.naturalmachines.com/

Figure 2.17:

By Maurizio Pesce from Milan, Italia (ChefJet Candy 3D Printer) [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:ChefJet_Candy_3D_Printer_(16675977970).jpg

Figure 2.18:

By grafvision - dental-prosthesis-PYR6RKL - Envato Elements:

https://elements.envato.com/

Figure 2.19:

By Grey_Coast_Media - doctors-hands-holding-silicone-mouth-guard-PGUYKJ5 - Envato Elements:

https://elements.envato.com/

Figure 2.20:

By Maikel Beerens, Xilloc [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], from Wikimedia Commons:

https://commons.wikimedia. org/wiki/File:Xilloc_Patient_Specific_Implant_Titanium.png

Figure 2.21:

By The U.S. Food and Drug Administration (3-D Printed Prosthetic Hand - blue (5229)) [Public domain], via Wikimedia Commons:

https://commons. wikimedia.org/wiki/File:3-D_Printed_Prosthetic_Hand_-_blue_(5229)_ (18492491235).jpg

Figure 2.22:

By CSIRO [CC BY 3.0 (

https://creativecommons.org/licenses/by/3.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:CSIRO_ ScienceImage_1761_3D_printed_titanium_horseshoes.jpg

Chapter 03:

By Pressmaster - new-device-P9ULWLQ - Envato Elements:

https://elements.envato.com/

Figure 3.1:

By dolgachov - happy-children-with-3d-printer-at-robotics-school-P248X6F -Envato Elements:

https://elements.envato.com/

Figure 3.2:

Used with permission from Makers Empire

Figure 3.3:

By Libraries Taskforce (Fab Lab in Exeter Library) [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons,

https://commons.wikimedia.org/wiki/File:Fab_Lab_in_Exeter_Library_(19744255694).jpg

Figure 3.4:

By Texas State Library and Archives Commission from Austin, TX, United States (Testing out the 3D printer) [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:Testing_out_the_3D_printer_(42000207351).jpg

Figure 3.5:

Used with permission from Dan DeVona

Figure 3.6:

Used with permission from Makerbot

Figure 3.7:

By Libraries Taskforce (Fab Lab at The Word) [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons,

https://commons.wikimedia.org/wiki/File:Fab_Lab_at_The_Word_(33923572260).jpg

Chapter 04:

By stokkete - 3d-printing-and-education-P6UENC3 - Envato Elements:

https://elements.envato.com/

Figure 4.8–9:

Used with permission from Eric Johnson

Figure 4.13–17:

Photo image courtesy of Jamber, Inc.

Figure 4.18–21:

Photo image courtesy of Lucas Phillips

Chapter 05:

By Pressmaster - using-innovation-PKWV69D - Envato Elements:

https://elements.envato.com/

Figure 5.2:

By Math buff [CC BY-SA 4.0 (

https://creativecommons.org/licenses/bysa/4.0

)], from Wikimedia Commons;

https://commons.wikimedia.org/wiki/File:Cartesian_xyz_ijk_coordinates.svg

Figure 5.4:

By Z22 [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], from Wikimedia Commons;

https://commons.wikimedia.org/wiki/File:Large_delta-style_3D_printer.jpg

Figure 5.5:

By Svjo [CC BY-SA 3.0 (

https://creativecommons.org/licenses/by-sa/3.0

)], from Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:Polar_ coordinate_system-2.png

Figure 6.2:

By Maurizio Pesce from Milan, Italia (3D Printing Materials) [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:3D_Printing_Materials_(16837486456).jpg

Chapter 07:

By Dirk van der Made [GFDL (

http://www.gnu.org/copyleft/fdl.html

) or CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], from Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:Schuifmaat_bottom_ mechaniek.png

Figure 7.2:

By Polygon data is BodyParts3D. (BodyParts3D) [CC BY-SA 2.1 jp (

https://creativecommons.org/licenses/by-sa/2.1/jp/deed.en

)], via Wikimedia Commons,

https://commons.wikimedia.org/wiki/File:Cervical_vertebrae_from_ BodyParts3D_on_MeshLab.png

Figure 7.3:

By Svitlana Lozova [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], from Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:Cura_software.jpg

Figure 7.14:

Photo image courtesy of Jamber, Inc.

Figure 7.16:

By JayLoerns [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], from Wikimedia Commons.

https://commons.wikimedia. org/wiki/File:Wireless_3D_Printing_with_AstroPrint_on_a_tablet.jpg

Chapter 08:

By microgen - extended-2d-printer-KD8CJMF - Envato Elements:

https://elements.envato.com/

Figure 8.1:

By Creative Tools from Halmstad, Sweden [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons;

https://commons.wikimedia.org/wiki/File:3D_Printshow_2014_ London - Fuel3D_portable_3D_scanner_v04_(14964238510).jpg

Figure 8.2:

By Ilya Voyager [CC0], from Wikimedia Commons;

https://commons. wikimedia.org/wiki/File:Reeb_foliation_half-torus_POV-Ray.png

Figure 8.3:

Responsive Device Mock-Up -

https://elements.envato.com/

- With a screen shot of a web site inside

Figure 8.5:

By CLS500 [CC BY-SA 4.0 (

https://creativecommons.org/licenses/bysa/4.0

)], from Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:3D_Printing_Dublin,_Interior.jpg

Figure 8.6-9:

Photo image courtesy of Harnek Gulati.

Figure 8.10:

Photo image courtesy of Dale Hawley.

Chapter 09:

By Pressmaster - architect-printer-P7SC7PM - Envato Elements:

https://elements.envato.com/

Figure 9.7:

Photo image courtesy of Lucas Phillips

Figure 9.8:

By JayLoerns [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], from Wikimedia Commons:

https://commons.wikimedia. org/wiki/File:AstroPrint_Cloud_Interface.jpg

Figure 9.9-11:

Photo image courtesy of Lucas Phillips

Figure 9.12:

By Thelema4ever [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], from Wikimedia Commons;

https://commons. wikimedia.org/wiki/File:Mobile_duper_3d_printer-500x500.jpg

Part 02:

By Maurizio Pesce from Milan, Italia [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:Ultimaker_3D_Printer_(16656068207).jpg

Chapter 10:

By Creative Tools from Halmdstad, Sweden [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:Fully_assembled_3D_ printable_wrench.jpg

Figure 10.8:

Photo image courtesy of Lucas Phillips/

Chapter 11:

By cookelma - three-dimensional-printing-machine-PDGAQQT -Envato Elements:

https://elements.envato.com

Figure 11.1:

By Maurizio Pesce from Milan, Italia (3D Printing Materials) [CC BY 2.0 (

https://creativecommons.org/licenses/by/2.0

)], via Wikimedia Commons:

https://commons.wikimedia.org/wiki/File:3D_Printing_ Materials_(16863368275).jpg

Chapter 12:

By Frank Schwichtenberg [CC BY 4.0 (

https://creativecommons.org/licenses/by/4.0

)], from Wikimedia Commons:

Chapter 13:

Photo image courtesy of Nina Buccacio

Figure 13.7-8:

Photo image courtesy of Nina Buccacio

Part 03:

By Rawpixel - business-people-using-digital-devices-PTA376M -Envato Elements:

https://elements.envato.com/

Figure 14.1:

By Svitlana Lozova [CC BY-SA 4.0 (

https://creativecommons.org/licenses/by-sa/4.0

)], from Wikimedia Commons:

https://commons. wikimedia.org/wiki/File:3D_printing_a_snow_machine_nozzle.jpg

Chapter 15:

By Rawpixel - digital-device-technology-equipment-gadget-P9SRD4T - Envato Elements:

https://elements.envato.com/

Figure 15.1:

By stokkete - engineering-students-using-a-3d-printer-PHSKHP4 -Envato Elements:

https://elements.envato.com/

APX A:

By stokkete - engineering-students-using-a-3d-printer-in-the-VPXWRGS - Envato Elements:

https://elements.envato.com/

APX B:

By stockasso - engineers-using-a-computer-PCTLJY9- Envato Elements:

https://elements.envato.com/

Index

By cookelma - 3d-scanner-optical-sensors-that-enable-high-PKCZJM2- Envato Elements:

https://elements.envato.com/

3D Printer Overview

CHAPTER 1 – A Brief Overview of 3D Printing

CHAPTER 2 – 3D Printer Use in Industry

CHAPTER 3 – 3D Printers and Education

CHAPTER 4 – Do-It-Yourself 3D Printing

CHAPTER 5 – Types of 3D Printers

CHAPTER 6 – Printable Materials including FDM Filament

CHAPTER 7 – Applications and Slicing Settings

CHAPTER 8 – Getting Started

CHAPTER 9 – Setting Up to Print

A Brief Overview of 3D Printing

OVERVIEW AND LEARNING OBJECTIVES

In this chapter:

•1.1 – What is 3D Printing?

•1.2 – What are the steps of the printing process?

•1.3 – What are some common parts used in a desktop 3D printer?

•1.4 – How was the technology for 3D Printers invented and first used?

•1.5 – What is the potential for 3D printers?

› 1.1 – What is 3D Printing?

When the word printer is used, most people think of a conventional printer they might use at home or in the office to print out text and images on paper. These printers print in a flat two-dimensional (2D) space using the dimensions length and width. A three-dimensional (3D) printer uses length and width but also adds depth to the print (see Figure 1.1). This transforms a flat print into a tangible, workable object you can hold and use.

FIGURE 1.1 – A number of 3D printed functional prototypes sliced in Ultimaker Cura and 3D printed on Ultimaker 3 Extended with PLA and water-soluble PVA. Svitlana Lozova.

BRIEF REVIEW OF TERMS

Three-dimensional (3D) Printer is a manufacturing tool that creates physical objects from a 3D model design using an additive manufacturing method that adds layers upon layers of material.

Envision the process as if you are printing a flat circle on a piece of paper lying on a table, and then you pull that printed circle “up” from the flat surface creating a physical cylinder. See Figure 1.2, which illustrates how a spire rises up from the flat surface during the 3D printing process.

FIGURE 1.2 – The printing head of a FELIX 3D Printer in action. Jonathan Juursema.

3D prints can take almost any form, depending on the size of the printer. After the initial printing process is completed, 3D prints can be linked or fused together to form larger objects. Figure 1.3 shows a complex object with individually printed parts in a variety of shapes that were assembled after printing.

Additive Manufacturing is a general term referring to a variety of fabrication processes that use a manufacturing tool to create a physical 3D object by adding material. A 3D printer is one subset of this type of manufacturing process because it continuously adds layer upon layer of material to build a physical 3D object.[1] This is different from subtractive manufacturing that takes material away from existing resources to create an object, or the consolidation processes that take smaller parts, combines them together, and fuses them to create the designed object.

FIGURE 1.3 – 3D print of a spool holder on a Printrbot Simple Metal 3D-printer. Creative Tools.

At its core, 3D printing is a manufacturing method that takes a digital design and creates a physical 3D object by building up layers of a selected material. In Figure 1.4, we see a printer adding material to create a robot layer-by-layer, with some finished printed robots to the right.

FIGURE 1.4 – Ultimaker 3D Printer. Maurizio Pesce.

BRIEF REVIEW OF TERMS

Additive Manufacturing is an overall term referring to a variety of fabrication processes that uses a manufacturing tool to create a physical object by adding layer upon layer of material. 3D printers are one subset of this type of manufacturing process. (like paper mache)

Consolidation Processes refers to a manufacturing method that uses the fusion of smaller individual parts or objects to bond and create a new object from a design. (like a brick wall)

Subtractive Manufacturing is a fabrication process that cuts or drills away from a solid material block to create an object. Industrial CNC (Computer Numerical Control) machining is a subset of this process. (like carving)

Watch video files located in the extras and on DVD to see 3D printers in action.

3D printers were first used as an innovative tool for industrial needs, most notably rapid prototyping. One of the greatest advantages of using a 3D printer is its ability to modify or create a unique object that you cannot obtain easily or that does not exist. This makes the use of 3D printing ideal for certain types of prototyping for tools and machine parts that in the past required molds.

Early printers were large and expensive to operate. With the advancements in technology, the costs of a 3D printer have decreased while the available sizes and functionality have increased. The types of materials and filaments have also seen advances and have greatly increased the variety of items created using a 3D printer. This has allowed greater use of 3D printers at the small business and consumer market levels.

BRIEF REVIEW OF TERMS

Filament is the raw thermoplastic material used in certain types of 3D printers.

Rapid Prototyping is a method that turns a digital design into a physical object using a quicker process, such as 3D printing, rather than traditional methods.

Today, desktop 3D printers can be found in homes, schools, public libraries, retail stores, and businesses along with an increased use in industrial manufacturing.

See Chapters 2 through 4 for how 3D printers are being used. See Chapter 6 for information on the types of materials and filaments available.

› 1.2 – What are the steps of the printing process?

Process overview

There are many ways to start a 3D print and we will go more in-depth on the 3D printing process in Part 2 of this book. However, in this section we will briefly describe the process it takes to create a 3D print. These steps generally remain the same for most types of 3D printers and are the cornerstones of 3D printing. Figure 1.5 shows a diagram depicting the steps and how they are related.

Obtaining a 3D model and refining the print are steps that have multiple methods of completion based on your project or equipment. The original source matter determines how a 3D model is created or obtained, while the amount of cleaning and refinement determines the methods of finishing.

FIGURE 1.5 – The 3D printing process.

BRIEF REVIEW OF TERMS

Model or Modeling is a digital design created by CAD software, 3D scanner, or digital camera.

MAKER’SNOTE

The method of creating the 3D model and finishing your print will vary depending on your project.

Obtaining a 3D Model

The 3D printing process starts with a digital design, or model. This model is a digital 3D representation of a solid object consisting of triangles. The surfaces of these triangles are stored in the computer file to describe the geometry of the model. All 3D objects and formats used in 3D printing use triangles to define the surface of a 3D model (see Figure 1.6).

There are many ways to create or obtain a 3D model like using computer programs, scanners and camera, or parametric mathematical equations.

FIGURE 1.6 – STL sample. Kaboldy.

■3D models can be created by designing the object within 3D animation, art, gaming, or computer aided design (CAD) software.

■3D scanners can scan the entire surface and sides of an object to create a 3D model. This includes digital cameras that take a 2D image and reconstruct and render to 3D using selected computer software.

■Parametric methods using mathematical equations can also be used to create 3D models. This method is sometimes used by online sites.

■Premade 3D models can also be downloaded from sites on the internet for both commercial and private use.

An example of obtaining a 3D model is when a maker wants to create a lens cap holder for their camera: they have a few options to obtain or create a 3D model. The maker could take measurements of the lens cap and camera strap and design the object using 3D modeling software. The maker could also search online for a premade model at the correct size or one that is modifiable.

BRIEF REVIEW OF TERMS

Computer Aided Design (CAD) is software that assists in creating or modifying a digital model or design.

Maker is the person who creates the 3D print.

Parametric refers to a mathematical equation that represents the points of an object.

This web link is an example of a premade lens cap holder a maker can download and use. Additionally, this example has a parametric object that can be customized.

https://www.thingiverse.com/thing:2004739

After obtaining a 3D model from one of these sources, the information must be converted into a file format that your slicing program understands.

Selecting a File Format

The most common file type for 3D modeling information is the Stereolithography (STL) format. You will likely encounter this file type when searching online for models. However, there are a number of usable file formats like: Object file format (OBJ), Additive Manufacturing File (AMF), and 3D Manufacturing Format (3MF). We will review some of the advantages and disadvantages of using different formats in Chapter 8.

BRIEF REVIEW OF TERMS

3D Manufacturing Format (3MF) is an XML-based data format developed and published by the 3MF Consortium. It is used to store model information like shape, color, and material.

Additive Manufacturing File (AMF) is an XML-based data format that stores model information like shape, color, and material.

Object file format (OBJ) is an older 3D model format used with various 3D editors.

Slice or Slicing is the act of translating a digital model into thin stratification layers.

Stereolithography (STL) file is a file format native to the stereolithography CAD software created by 3D Systems. STL has several after-the-fact backronyms such as “Standard Triangle Language” and “Standard Tessellation Language”. It is now a file format that holds 3D modeling and slicing information readable by a 3D printer.

Slicing the 3D Model

After your object is in a usable file format, use slicing software to slice your object into printable layers and prepare your object for print. We will talk more about both free and purchasable slicing software in Chapter 7.

The slicing program—according to your settings—checks for errors, slices the 3D object into layers, adds supports where needed, and makes fill patterns for the interior. The 3D printer uses this information and slices to print the object layer-by-layer. Figure 1.7 shows an example of a 3D object within a slicing program.

FIGURE 1.7 – A 3D model within the slicing software that shows the layers and infill. Jonathan Torta.

In the slicing program, software tests are run to check for errors in the design. The slicing program checks for problems such as overlapping sides, unaligned gaps, intersecting faces, or a non-manifold object.

For example, all 3D models are created by defining the surface of the object, and it is required that the object be manifold or watertight. Essentially, the 3D model is not solid. It is hollow and should be able to hold water if filled. A problem occurs if the object is not watertight and does not have all of the edges continuously connected. The slicer program may fail to correctly slice the object. Any errors can affect the quality of the slice. We will take a closer look at the types of errors and their causes in Part 2.

BRIEF REVIEW OF TERMS:

Infill is structures added for strength in enclosed empty or hollow areas in a 3D print.

Manifold is when 3D model geometry is “water-tight”. Has a contiguous and defined exterior and interior.

Non-manifold is when a 3D model geometry is not contiguous like unwanted holes or has errors like intersecting edges.

Supports Additional printed structures that secure portions of printed objects that overhang greater than 45 degrees.

MAKER’S NOTE

Various slicing applications have different parameters and may flag different errors. They may also indicate whether the errors are fixed automatically or manually. However, slicing application error-checking is not fool-proof: the errors found are very dependent on the error checking implementation—some slicers may have a more robust error-checking implementation, others may just flag the errors.

Slicing applications are not the only way to catch errors. Online validators and dedicated model editing applications are a few examples of other ways. Catching any errors before importing the 3D model into the slicing program is preferable.

Mechanical structures, like supports and rafts, may need to be created for the object to be printed correctly (see Figure 1.8). These supportive structures are removed from the object after printing.

FIGURE 1.8 – The support structures for a LEGO® block. PranjalSingh IITDelhi.

The slicing software then slices and converts the design into thin layers as a blueprint, or G-code, that the 3D printer follows to create the print, layer by layer. This code carries all the instructions that the printer needs to print the object, like temperatures (hot end and bed), paths of each layer, and fan start and stop times.

MAKER’SNOTE

The slicing programs can use additional proprietary codes other than generic G-code for the printer to follow.

BRIEF REVIEW OF TERMS:

Bed is the printing surface area where the 3D print is made.

G-code is a numeric control programming language that communicates the slicing information to the printer. This includes speed, location and path directions.

Hot End is the component where the filament is melted to a desired temperature.

Printing

There are a variety of ways you can access a 3D printer. Some of the more common are buying or building your own printer like retail stores (like hardware and computer stores) and kits. Other ways to gain access to 3D printing is renting, public libraries, makerspaces, or online services.

MAKER’SNOTE

It is recommended to conduct research on types of printers or printing services to find one that will best fit your printing needs for size, material, timeframe, and quality.

After the slicing program is finished, the sliced model information is then communicated to the printer by connecting your computer using Universal Serial Bus (USB) cable, Wi-Fi, or Secure Digital (SD) card. See Figure 1.9 for a closer look at a connected laptop with an open slicing program with a 3D model being sent to the printer. Online services will have their own upload process.

FIGURE 1.9 – A typical 3D printing setup, including a FELIX 3D Printer currently printing, a Macbook running 3D printing software, and some example 3D printed objects. Jonathan Juursema.

BRIEF REVIEW OF TERMS:

Secure Digital (SD) Card is a removable data card for mobile devices.

Universal Serial Bus (USB)Cable is a data transfer cable that can connect devices.

Wi-Fi can send data to devices without a physical connection.

Depending on the type of 3D printer, a variety of materials can be used, including plastics, metal, ceramics, glass, paper, and food (like chocolate). We will talk more about the different types of printable materials in Chapter 6.

The printer then prints the object; a print can take several hours. The 3D printer does exactly what computers and machines do best, methodically and precisely follow instructions—in this case tracing a line of plastic (or other material) layer-by-layer (see Figure 1.10). After the printer is finished laying down the layers of material to create the object, any support structures can be removed.

FIGURE 1.10 – 3D Printer Shootout Testing – Day 3. John Abella.

Refining the Print

After the print is complete, some refinements may need to be done before the object is finished, like cleaning and removing any stray material. Because the printing process involves the bonding of material layers to create the object, the stratification will show in the print. There are several different methods to smooth or cover the layers. A few examples are sanding and painting. Figure 1.11 shows a 3D printed replica that was finished for display. We will cover finishing in Chapter 13.

FIGURE 1.11 – A 3D printed tactile replica of the Tsar Cannon. Mos.ru.

› 1.3 – What are some common parts used in a desktop 3D printer?

3D printers can be operated by a variety of printing methods. We will cover some of the more common ones in Chapter 5. In this book, we are showcasing a type of 3D printer known as Fused Deposition Modeling (FDM).

An FDM printer is one of the more popular desktop 3D printers on the market today. They work by heating up thermoplastic filament to a desired melting point then extruding the heated material layer on top of material layer to form a 3D object. Or another way of thinking of it is as a computer-controlled hot glue gun that builds an object layer by layer. We will use this printer type to show a few of the more common parts and their function.

BRIEF REVIEW OF TERMS

Fused Deposition Modeling (FDM) refers to the process of depositing continuous heated material in layers to create an object. Because this term is trademarked by Stratasys Inc., the term Fused Filament Fabrication (FFF) was created and can be used in place of FDM.

Thermoplastic is a type of plastic that can repeatedly become pliable when heated at a specific temperature and reverts to a solid state when cooled.

FIGURE 1.12 – A 3D printer with labeled parts. Jonathan Torta.

MAKER’SNOTE

Depending on the type of 3D printer, the parts and their locations may differ from the diagram. See Chapter 5 for a more in-depth list of parts and their functions.

Understanding the parts of a 3D printer will help you gain knowledge in the inner workings of the printer along with those components you can adjust or modify to ensure the quality of your print (see Figure 1.12). If you buy or build your own printer, you will need to maintain it for consistent optimization.

The common parts of a 3D printer include:

1.Bed – The printing surface area of the 3D printer. This is the component where the 3D print is deposited. It can be made of a variety of different materials including plastic, metal or glass.

2.Build area – The overall size of the printable area that determines how large of an object can be printed. This includes the XYZ or width, height, and depth dimensions. Some build areas are cubical while others are cylindrical.

3.Cold end – The part of the extruder where the filament is pulled from the spool then fed through or to the print head.

4.Cooling fan – There can be multiple cooling fans located within a 3D printer. These fans help cool areas including the extruder motor, print head, and newly extruded filament for some types of materials.

5.Extruder – or print head is a motorized device that has two assemblies: the cold end and the hot end. The cold end pulls filament and feeds it to the hot end that in turns heats the filament before the material exits through the nozzle into the build area.

6.Filament spool – The mounting location for the spool of material for feeding into the extruder.

7.Hot end – The part of the extruder where the filament is heated and melted to a desired temperature.

8.Linear rod or rails – Used to help the print head (or bed) to move around reliably during printing.

9.Nozzle – A small metal device with a fixed-size hole where heated plastic is sent through into the build area. Different size nozzles are used depending on the type of object being printed.

10.Local controller – A device that controls and gives commands to your printer without a computer.

› 1.4 – How was the technology for 3D Printers invented and first used?

3D printing has become more common in everyday life and in pop culture in recent years. Because of this, it is often thought of as a new technology. However, the technology was invented and first used over 30 years ago. In the early 1980s, the first 3D printer capable of printing a physical part was invented by Charles (Chuck) Hull.[2] Other inventors built upon this groundbreaking technology to develop new machines, printer parts, and materials. The use of 3D printers started to expand and become more accessible.

The traditional manufacturing method of prototyping parts and tools was a long and laborious process, often using the subtractive method and carving out molds. Any changes to the design would often lead to starting the whole process again from the beginning. The use of additive manufacturing, including 3D printers, in the field greatly increased the speed and efficacy certain types of prototypes can be made or modified. The term rapid prototyping in this context refers to this method and spotlights the overall speed and effectiveness 3D printing brought to this section of industry. Designers could now test a tool or part design using a faster print-on-demand production method and use less expensive materials, allowing them increased flexibility to create or modify their designs.

With the continued advancement in 3D printer technology and materials, its use is expanding beyond rapid prototyping into the rapid manufacture of tools, parts, and products. This ability to effectively create multiple commercial end use products has opened the door for 3D printers in a vast number of industries and uses. We will illustrate some of these industries and uses in Chapter 2.

› 1.5 – What is the potential for 3D printers?

With the cost of buying or building personal 3D printers decreasing, the availability of commercial 3D printing services, a wider array of materials, and the ever-expanding creative uses in industry, the potential for 3D printers’ use is expanding.

When 3D printers were first created, they were used in specialized industries and were too expensive for small business or home use. This changed with advances in technology, like the advent of cheap microcontrollers and stepper motors, that lowered the overall cost and increased the demand. This allowed Do It Yourself (DIY) enthusiasts, schools, and small businesses to buy or build their own 3D printers (see Figure 1.13). The expansion and evolution of materials are also helping expand the growth and the creative uses of a 3D printer.

FIGURE 1.13 – A maker using a 3D printer. monkeybusiness.

BRIEF REVIEW OF TERMS

Do It Yourself (DIY) is a phrase describing enthusiasts that build or modify objects without a professional craftsman.

With the flood of new users, the popularity of 3D printers grew, taking 3D printing from an intriguing novelty to a large presence in our pop culture. Television shows, movies, books, and video games all have featured 3D printers. For example, in the video game Prey, developed by Arkane Studios, the player used recycled material and a 3D printer to fabricate usable items.

Another example is the reboot of the television show Lost in Space, produced by Netflix. The crew uses a 3D printer in their spaceship to fabricate needed parts after crash-landing. The show Cloak & Dagger by ABC Signature Studios and Marvel Television showcased a 3D printer creating, layer-by-layer, a figurine of one of the protagonists. The printing scenes also showed supports being used and the finishing of the print. In the film Ocean’s Eight by Warner Bros. Pictures, both a 3D scanner and a 3D printer were used in recreating jewelry.

While the growth of 3D printer use in the home or small business is becoming more commonplace, some of the real potential is still behind-the-scenes in industry. Some of the fascinating and rapid advances have been in the medical, dental, manufacturing, and aerospace fields. In Chapters 2 through 4, we will take a closer look into some of these fields along with how they are being used in education and in the home. We hear from Scott Higby for his thoughts on the potential of 3D printers in art classes.

QUOTE

SCOTT HIGBY

HS/MS ART TEACHER, AFTON CENTRAL SCHOOL

I think they [3D printers] would have great potential for any graphic design or sculpture classes that I teach. I had one of my advanced art students do a 3D project where he designed some engine parts and printed them on a 3D printer. I think students, if given the opportunity, would love to learn more about 3D printers.

SUMMARY

The technology for 3D printers was invented over 30 years ago but has become more common in recent years because of the advent of inexpensive microcontrollers, stepper motors, and advances in technology. The potential of using 3D printers has grown and the cost has lowered. Unlike a flat two-dimensional (2D) printer, a three-dimensional (3D) printer uses length, width, and depth to make objects by using the additive manufacturing process of adding layer upon layer of materials. There are many steps in the 3D printing process, such as obtaining a 3D model, selecting a file format, slicing the 3D model, printing, and refining the print. There are at least nine common parts of a 3D printer (bed, build area, cold end, cooling fan, extruder, filament spool, hot end, linear rod or rails, and nozzle). The next chapters will present in-depth information about 3D printer use in society.

APPLYING WHAT YOU’VE LEARNED

1.Start your own 3D dictionary by adding the definition (in your own words) of five words relating to 3D printing that you did not know before.

2.In the future, what do you think 3D printers will be able to do and why?

3.Describe a project you would like to make with a 3D printer and why would you like to make it.

4.What is the first process you must do when starting to make a 3D print and where would you find the information?

5.Explain what a 2D printer and a 3D printer are and how they are different and the same.

6.Explain one of the greatest advantages of using a 3D printer and give some examples.

7.Briefly describe the process of the flow chart in this chapter in your own words.

8.Describe eight parts of a 3D printer and how they are used.

9.What manufacturing process is 3D printing a subset of? Describe this manufacturing process?

10.In your own words, how are the terms CAD, G-Code, modeling, raft, slicing, and supports used in 3D printing?

11.Describe the three manufacturing processes and how are they different from each other.

12.Draw your own picture of a 3D printer and label each part.

REFERENCES

[1] – http://additivemanufacturing.com/basics/

[2] – https://www.3dsystems.com/our-story

3D Printer Use in Industry

OVERVIEW AND LEARNING OBJECTIVES

In this chapter:

•2.1 – How are 3D printers being used in industry?

•2.2 – What is the potential growth of 3D printer use in industry?

Although 3D printers were first utilized in industry, they have expanded almost everywhere, including small businesses, education, and consumer markets. In this chapter we will highlight a few ways 3D printers are being used in a cross-section of industries and businesses such as:

■Aerospace

■Archeology

■Architecture

■Culinary arts

■Dentistry

■Entertainment

■Medical

We will also talk with several makers to hear their firsthand accounts on how 3D printers are incorporated into their occupations.

What fields are you interested in? Do a web search on how 3D printers are changing or enhancing those industries or hobbies.

This chapter notes several web URLs. These links are also in the extras and on the DVD in an interactive PDF for quick viewing.

› 2.1 – How are 3D printers being used in industry?

Industries ranging from automobiles to architecture, to art, to fashion all use 3D printers. Because each field has specific production requirements, 3D printers have evolved to fit the needs of a particular industry by inventing new printing processes and developing new materials.

The link below is to a PBS news segment talking about evolving 3D printers by developing new custom printers and print methods to decrease production time and costs while maintaining the quality of the product.

https://youtu.be/Adl1Sn86ojs

3D printers are changing production and workflows within industry in many ways. In Figure 2.1 we see a mechanical part being printed as an example of rapid prototyping.

It is important to understand that 3D printers come in all shapes, sizes, and use a variety of printing techniques and materials. This range includes large printers that can print houses, to printers using robot arms, to printers that use lasers during the printing process. Most industrial printers are not the desktop types you would find in schools, libraries, or the home. They often are specialized and use more complex printing processes. In Chapter 5, we will discuss a few types of 3D printers and showcase how they may differ in the printing process.

FIGURE 2.1 – Mojo 3D Printer. Intel Free Press.

For this section, we are highlighting a few industrial fields to show examples of the wide range of uses and how 3D printers are changing our world.

Aerospace

The aerospace industry is a driving force in innovation and their use of 3D printers is no exception. The 3D printers’ ability to prototype rapidly is a natural fit for testing aircraft and spaceship design. However, their use has expanded beyond concepts into manufacturing machine parts and printing on-demand in space.

The National Aeronautics and Space Administration (NASA) is utilizing 3D printers both in space and on the ground and is driving the evolution of additive manufacturing and 3D printers.

Spacecraft machined parts

When you think of 3D printing, you may not think of the ability to print rocket parts for spacecraft; however, with the advances in printing technology and materials, they are able to do just that. NASA facilities have worked together to combine existing 3D printing processes to create complex mechanical parts. This has lowered costs and sped up the manufacturing timeline.

One example is NASA’s development of a rocket part called a pogo accumulator. Being able to 3D print the part reduced the need for over 100 weld points. This reduced the overall cost by over 30 percent and build time by over 80 percent. The part was successfully tested and has led the way for further development in printing rocket components.[1] Another example of time savings is the 3D printing of large titanium satellite fuel tanks by Lockheed Martin. Production time was cut from two years to three months.[2]

NASA also created new 3D printing processes to fit specific needs, most notably to maintain quality in extreme temperatures and pressures. An example is the printing of rocket engine nozzles. These nozzles are complex parts, subject to extreme heat and cold. They have channels within the structure that must be precisely sealed to contain the high-pressure coolant. A new wire-based method of 3D printing was developed called the Laser Wire Direct Closeout (LWDC) technique. Using this process, NASA was able to print the nozzle, close the coolant channels, and create supports to help with structural loads during operation. The nozzles have been successfully tested and now have the potential to reduce production time from months to weeks.[3]

In Figure 2.2, we see an example of a 3D printed combustion chamber rocket part being tested for quality. This part was printed using a combination of different printing techniques that reduced the overall number of parts to increase durability and decrease production from weeks to hours. [4]

See the testing in action:Low Cost Upper Stage-Class Propulsion project (LCUSP)

https://youtu.be/FfeP4BVTsps

Print on-demand in space

Space travel is like a very long hiking trip into the wilderness. Whatever items you will need during the trip, you must carry with you. Cargo space and weight become issues, along with deciding what you should bring to cover any unexpected occurrences during the trip. The more you bring, the better prepared you are, but the more difficult it is to carry everything. Depending on where you hike, your survival could depend on your decisions. For space travel, you have the added issues of carrying the power needed to escape our atmosphere or carrying all the materials needed to start a surface-side base.

FIGURE 2.2 – NASA successfully hot-fire tested a 3D printed copper combustion chamber liner with an E-Beam Free Form Fabrication manufactured nickel-alloy jacket. The hardware must withstand extreme hot and cold temperatures inside the engine as extremely cold propellants are heated up and burned for propulsion. NASA/MSFC/David Olive.

A goal for NASA was to develop a way to work around some of these issues. They looked to 3D printers and the ability to print on-demand. The ability to print parts and tools when needed decreases the number of things you need to launch with you and gives you flexibility with unknown incidents. While this might help solve the issue of what to bring, a few questions are still to be answered.

■