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Index

S.No Content Page No

1 Introduction 3

2 History 4-5

3 An overview of 3d printing technology 6-7

4 3D Printing Working 8-10

5 Colour Modelling 11

6 Z Corp.s 3D printers produce high- 12


resolution models

7 Applications of 3D printer 13-19

8 Specifications of 3D Printer 20

9 Conclusion 21

10 How can we get employment with 3d 22


printing technology

ABSTRACT

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The last two decades ended in the midst of revolution caused by a
technology that was barely noticeable at the beginning of the decade. In
1980 few would have guessed that personal computer along with desktop
publishing software would fundamentally change the way of our industry did
business. In 1990 again internet was known and used by a relatively small
set of people. Yet by the end of the decade it was a major force in our
industry and in society and in economy.

Once again we are facing anew decade and we have to wonder what the
next dominant technology likely to change our way of life is. While there is a
number of candidates for the next big technology including perennial
favorite, the free energy device, our best is the technology called 3D printing
which as the name implies is a technology that literally prints real 3D
objects. It is used by the marketing industry to create models for marketing
focus groups and pre-production sales demonstration.

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INTRODUCTION

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Originally developed at the Massachusetts Institute of Technology
(MIT) in 1993, .3DP technology creates 3D physical prototypes by
solidifying layers of deposited powder using a liquid binder. By definition
3DP is an extremely versatile and rapid process accommodating geometry of
varying complexity in hundreds of different applications, and supporting
many types of materials. Utilizing 3DP technology, Z Corp. has developed
3D printers that operate at unprecedented speeds, extremely low costs, and
within a broad range of applications. 3D printers are used by leading
manufacturers to produce early concept models and product prototypes .This
paper describes the core technology and its related applications.

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HISTORY

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3d printing technology was originally developed in Massachusetts
Institute of Technology. First 3 D Printer was launched in 1998. First 3D color
printer was launched in 2000. Introduced High definition 3D Printing in 2005.
HD3DP concept is the result of a combination of print-head technology,
materials advancement, firmware, and mechanical design.

SOURCE DATA
3D printing technology leverages 3D source data, which often takes the form
of computer-aided design (CAD) models. Mechanical CAD software
packages, the first applications to create 3D data, have quickly become the
standard for nearly all product development processes. Other industries such
as architectural design have also embraced 3D technologies because of the
overwhelming advantages they provide, including improved visualization,
greater automation, and more cost-effective reuse of 3D data for a variety of
critically important applications. Due to the widespread adoption of 3D-based
design technologies, most industries today already create 3D design data and
are capable of producing physical models with 3D printers. The software that
drives the 3D printers accepts all major 3D file formats, including .stl, .wrl,
.ply, and .sfx files, which leading 3D software packages can export. In
addition to mainstream applications in mechanical and architectural design,
3D printing has expanded into new markets including medical, molecular, and
geospatial modeling. Additional sources of data include CT/MRI diagnostic
data, protein molecule modeling database data, and digitized 3D-scan data. As
designing and modeling with 3D technologies has become more pervasive,
developers have created a large number of software packages tailored for use
in specific industries. A small sampling of 3D software packages that are
directly compatible with the 3D printers appear in the table below.

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After exporting a solid file from a 3D modeling package, users can open the
file in ZPrint, the desktop interface for Z Corp.s 3D printers. The primary

SolidWorks Maya RapidForm 3D Studio


Viz
Pro/ENGINEE SketchU Alias Form Z
R p
CATIA RasMol Raindrop VectorWorks
GeoMagic
3D Studio Rhino Inventor Mimics
Max
function ofZPrint is to cut the solid object into digital cross sections, or
layers, creating a 2D image for each 0.1016mm (0.004) slice along the z
axis. In addition to sectioning the model, users can utilize ZPrint to address
other production options, such as viewing, orienting, scaling, coloring, and
labeling multiple parts. When a user decides to print the job, ZPrint software
sends 2D images of the cross sections to the 3D Printer via a standard
network, just as other software sends images or documents to a standard 2D
printer. Setup takes approximately 10 minutes.

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AN OVERVIEW OF 3D PRINTING
TECHNOLOGY

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BLOCK DIAGRAM
The microcomputer is used to create a 3 Dimensional model of
the component to be made using well-known CAD techniques. A
slicing algorithm is used to identify selected successive slices, i.e., to
provide data with respect to selected 2-D layers, of the 3-D model.
Once a particular 2D slice has been selected, the slice is
then reduced to a series of one dimensional scan lines. Each of the
scan line may comprise of single line segments or two or more
shorter line segments. Each line segment having a defined starting
point on a scan line and a defined line segment length
The microcomputer actuates the powder distribution
operation when a particular 2-D slice of the 3-D model which has
been created has been selected by supplying a powder START
signal to a powder distribution controller circuit which is used to
actuate a powder distribution system to permit a layer of powder
for the selected slice to be deposited as by a powder head device.
The powder is deposited over the entire confined region within
which the selected slice is located.
Once the powder is distributed, the operation of powder
distribution controller is stopped when the microcomputer issues
a powder STOP signal signifying that powder distribution over
such region has been completed.
Microcomputer then select a scan line i.e., the first scan
line of the selected 2-D slice and then select a line segment, e.g.,
the first 1-D line segment of the selected scan line and supplies
data defining the starting point thereof and the length thereof to a
binder jet nozzle control circuit. For simplicity in describing the
operation it is assumed that a single binder jet nozzle is used and

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that such nozzle scans the line segment of a slice in a manner such
that the overall 2-D slice is scanned in a conventional raster scan
operation. When the real time position of the nozzle is at starting
point of the selected line segment. Nozzle is turned on at the start
of the line segment and turned off at the end of line segment in
accordance with the defined starting point and length data
supplied from the computer for that line segment. Each successive
line segment is similarly scanned for the selected scan line and for
each successive scan line of the selected slice in the same manner.
For such purpose nozzle carrier system starts its motion with a
scan BEGIN signal from microcomputer. So that it is moved in
both x-axis direction and in the Y-axis direction. Data as to the
real time position of the nozzle carrier is supplied to the nozzle
control circuit. When the complete slice has been scanned, a scan
STOP signal signifies an end of the slice scan condition.

Block Diagram

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3D PRINTING WORKING

3D printers use standard inkjet printing technology to create


parts layer-by-layer by depositing a liquid binder onto thin layers of
powder. Instead of feeding paper under the print heads like a 2D
printer, a 3D printer moves the print heads over a bed of powder
upon which it prints the cross-sectional data sent from the ZPrint
software. The system requires powder to be distributed accurately
and evenly across the build platform. 3D Printers accomplish this
task by using a feed piston and platform, which rises incrementally
for each layer. A roller mechanism spreads powder fed from the feed
piston onto the build platform; intentionally spreading approximately
30 percent of extra powder per layer to ensure a full layer of densely
packed powder on the build platform. The excess powder falls down
an overflow chute, into a container for reuse in the next build.

Once the layer of powder is spread, the inkjet print heads print
the cross-sectional area for the first, or bottom slice of the part onto
the smooth layer of powder, binding the powder together. A piston
then lowers the build platform 0.1016mm (0.004), and a new layer
of powder is spread on top. The print heads apply the data for the
next cross section onto the new layer, which binds itself to the
previous layer. ZPrint repeats this process for all of the layers of the
part. The 3D printing process creates an exact physical model of the
geometry represented by 3D data. Process time depends on the height
of the part or parts being built. Typically, 3D printers build at a
vertical rate of 25mm 50mm (1 2) per hour.

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When the 3D printing process completes, loose powder
surrounds and supports the part in the build chamber. Users can
remove the part from the build chamber after the materials have had
time to set, and return unprinted, loose powder back to the feed
platform for reuse. Users then use forced air to blow the excess
powder off the printed part, a short process which takes less than 10
minutes. Z Corp. technology does not require the use of solid or
attached supports during the printing process, and all unused material
is reusable.

3D printing is fast

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3D printing is the fastest additive technology commercially
available on the market. Other companies often refer to their
equipment as 3D printers, however these systems rely on processes
using a vector approach or single-jet technology to deposit all build
material. Z Corp. uses inkjet print heads with a resolution of 600 dpi
(dots per inch), focuses on a drop-on-demand approach, and
manufactures the only true 3D inkjet printers available. The
technology allows printing of multiple parts simultaneously, while
only adding a negligible amount of time to the print time for one
part.

The fundamental inkjet approach is the primary contributor to


greater speed, although there are several other reasons why this
system is the fastest. ZPrint software processes data in parallel with
the printing of the part. While the 3D printer deposits the first layer,
the software slices and processes the fifth layer. Some additive
technologies process all tool paths before the job begins. Although
the processing time may seem to be fast, it is often only a fraction of
the total time it takes to build the part. It can actually take up to an
hour to prepare a job with multiple parts using some additive
technologies.
3D printers enable the stacking of parts vertically because they do
not require rigid support structures. Producing parts with other types
of additive technologies requires structural supports along the
vertical axis, limiting the ability to stack or nest parts. With this 3D
printers, users can utilize the entire build area and produce multiple
parts with only one set-up procedure, further reducing the total
number of builds and processing time.

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COLOUR MODELLING

When printing 2D images from digital files, computers


convert the RGB values (Red, Green, and Blue colors displayed on
the monitor) to CMYK colors (Cyan, Magenta, Yellow, and Black).
Typically, a 2D color desktop printer will have a print head with
three of the color channels, CMY, and another for black, K. Using
these four inks, the printer combines several dots in each printed
pixel though the use of ordered dither patterns to create the
appearance of thousands of colors. The same principle applies to 3D
printing. 3D printers use four colored binders: cyan, magenta,
yellow and clear, to print colors onto the shell of the part. ZPrint
software communicates color information to the printer within the

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slice data. Full-color 3D printing produces prototypes with the same
coloring as the actual product. Users also use color to represent
analysis results directly on the model or to annotate and label design
changes to further enhance the communication value of the model.

While color can be an essential communications tool, many


3D software packages do not provide a simple way to produce 3D
files that include color data. To address this challenge developed
ZEdit software, a Microsoft Windows based program that
facilitates the addition of color data to 3D part files. ZEdit is a tool
for part coloring, markup, labeling, and texture mapping. Users also
utilize it to map .jpeg files onto 3D part geometries. ZEdit software
works with files from any of the leading 3D software packages.

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Z Corp.s 3D printers produce high-
resolution models

Z Corp. first introduced high-resolution 3D Printing


(HD3DP) in 2005. The HD3DP concept is the result of a
combination of print-head technology, materials advancement,
firmware, and mechanical design. Highly engineered inkjet print
heads, with 600-dpi, high-resolution capabilities, are the product of
years of research. Z Corp. leverages the engineered print heads in
combination with proprietary firmware to control the print head
during the printing process, accurately and precisely depositing
colored binder in the areas indicated by the ZPrint software.
Additionally, this 3D printers control the print head movement while
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positioned extremely close to the powder, reducing inaccuracies
related to fanning of the binder spray.

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APPLICATIONS Of 3D PRINTER

ADVANTAGES

1) 3D printing is Affordable
3D printers produce very little waste. The unprinted powder
surrounds and supports complex parts during printing. Users can
reuse all unused support powder. Thus, printed-part volume becomes
the basis for all part-creation costs. Other additive processes require
the building of solid support structures to support complex
geometries during the printing process. Users have to discard these
support structures after use, and the wasted material contributes
significantly to the cost of additive technologies.
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3D printers are dependable and easy-to-use, resulting in low
operating costs. Modular design and standard inkjet printing
technology combine to produce a reliable system that is
straightforward to operate and easy to maintain. The use of an off-
the-shelf print head allows for inexpensive, quick replacement of
the systems primary consumable component. The application of
modular design techniques to the printers electronics, printing, and
maintenance components makes the printers efficient to maintain
with minimum downtime, further reducing costs.

2) 3D printers are easy to use


The straightforward user interface and simple part-making
process make 3D printers accessible to everyone involved in product
design. The materials used are non-toxic, completely safe, and do not
require specialized operating environments such as a lab or a shop.
Users can operate 3D printers right in an office rather than in a
designated space with specialized requirements. Because of the
intuitive ZPrint software interface and simple set-up procedures,
anyone can efficiently operate one of 3D printers, eliminating the
need for a dedicated machine operator. The reliable technology
allows its 3D printers to run unattended during the printing process,
reducing user interaction to the simple setup and part removal steps,
which generally take less than one hour.
The process of bonding loose powder to solidify into parts is
compatible with many types of materials. While the 3D printer
remains exactly the same, users can change the build material to
produce parts with a wide range of material properties to meet
various application requirements. Z Corp. offers five materials and

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continues to develop other materials to provide performance
enhancements for additional applications. Users can select the best
material to support the needs of a specific application.

3) Speed
3D Printers are the fastest.5-10x faster than other RP
technology.A part can be printed at rate of 25mm vertical per hour. In
todays competitive global market speed in product development has
become a critical factor for success.

4) Affordability
Z Corporation sets the standard for affordability in 3D
printing. Because Z Corporation printers leverage standard inkjet
printing technology, they are more reliable and affordable. The
approach results in material usage costs that are a fraction of other
rapid prototyping technologies; finished parts cost $.10 USD per
cubic centimeter in materials. A handheld part can be produced for
about $10 USD in material costs. Z Corporation 3D printers recycle
all unused material, so you only pay for the actual materials used to
produce a part.

5) High-Quality Color
Z Corporation 3D Printers operate like a 2D desktop inkjet
printer, allowing for the use of multiple print-heads to support full-
color printing with dramatic increases in speed. Full,24-bit color
capabilities use colored binder materials (cyan, magenta, and yellow,
just like a 2D printer) to produce millions of distinct colors. Full-
color printing allows the addition of annotations, engineering labels
and texture maps. Z Corporations introduction ofHD3DP (High-

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Definition 3D Printing) capabilities also supports the production of
models having complex geometries and small, detailed features.

6) Versatile
The process of bonding loose powder to solidify into parts is
compatible with many types of materials.While the 3D printer
remains exactly the same.users can change the build material to
produce part with wide range of material property to meet various
application requirement.

BUILDING MATERIALS
1) High-Performance Composite Material makes strong, high-
definition parts and is the material of choice for printing color parts.
The most widely used material, high-performance composite
material enables color HD3DP on the 600-dpi platform 3D printer.
Fine resolution on small features and excellent strength make this
material suitable for applications ranging from concept modeling to
sand-casting patterns. It consists of a heavily engineered plaster
material with numerous additives that maximize surface finish,
feature resolution, and part strength. This material is ideal for:
1 High-strength requirements
2 Delicate or thin-walled parts
3 Color printing
4 Accurate representation of design details

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2) Direct Casting Metal Material creates sand-casting molds for
non-ferrous metals. This material is a blend of foundry sand, plaster,
and other additives that when combined produce strong molds with
good surface finishes. Direct casting metal material can withstand the
heat required to cast non-ferrous metals. Users of this ZCast
process can create prototype castings without incurring the costs and
lead-time delays of tooling.

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3) Investment Casting Material fabricates parts that users dip in
wax to produce investment casting patterns without molds or
geometric constraints. The material consists of a mix of cellulose,
specialty fibers, and other additives that combine to provide
an accurate part while maximizing wax absorption and
minimizing residue during the burn-out process. Users utilize
investment casting material to create high quality castings with
excellent surface finishes in a number of industries.

4) Snap-fit material creates Snap- parts with plastic-like,


flexural properties, Which are ideal for snap-fit applications. Z
Corp. has optimized this material for infiltration with the Z-
Snap epoxy. Users utilize snap-fit material to create plastic-like
parts that snap into other components and assemblies.

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5) Elastomeric Material creates parts with rubber-like
properties. Optimized for infiltration with an elastomer, this
material system consists of a mix of cellulose, specialty fibers,
and other additives. Users utilize elastomeric material to produce
accurate parts that are capable of absorbing the elastomer, which
gives the parts their rubber-like properties.
The microcomputer is used to create a 3 Dimensional model
of the component to be made using well-known CAD
techniques.A slicing algorithm is used to identify selected
successive slices, i.e., to provide data with respect to selected 2-D
layers, of the 3-D model.
Once a particular 2D slice has been selected, the slice is
then reduced to a series of one dimensional scan lines. Each of the
scan line may comprise of single line segments or two or more
shorter line segments.Each line segment having a defined starting
point on a scan line and a defined line segment length.
The microcomputer actuates the powder distribution
operation when a particular 2-D slice of the 3-D model which has
been created has been selected by supplying a powder START
signal to a powder distribution controller circuit which is used to
actuate a powder distribution system to permit a layer of powder
for the selected slice to be deposited as by a powder head device.
The powder is deposited over the entire confined region within
which the selected slice is located.
Once the powder is distributed, the operation of powder
distribution controller is stopped when the microcomputer issues
a powder STOP signal signifying that powder distribution over
such region has been completed.

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Microcomputer then select a scan line i.e., the first scan line of
the selected 2-D slice and then select a line segment, e.g., the first
1-D line segment of the selected scan line and supplies data
defining the starting point thereof and the length thereof to a
binder jet nozzle control circuit. For simplicity in describing the
operation it is assumed that a single binder jet nozzle is used and
that such nozzle scans the line segment of a slice in a manner such
that the overall 2-D slice is scanned in a conventional raster scan
operation.

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SPECIFICATION OF 3D PRINTER

Some of 3D printers available in the market are :-


1) Z printer 310
2) Spectrum Z 510 3) Z printer 45
1) Z printer 310 [Industrial strandate Monochrome 3D printing
system]

Equipment Dimension
74 * 86 * 109cm
Equipment weight
115 Kg
Power Requirement
115 V, 4.3 A or 230 V / 2.4 A
Resolution; 300 * 450 dpi
Build speed; 2 4 layers per minute
2) Spectrum Z-510 [next generation H D colour 3DP]

Equipment Dimension: 107 * 79 * 127cm


Equipment weight - 204 Kg
Resolution-600*540dpi
Power-100V, 7.8A or 115V, 6.8A or 230V, 3.4A

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CONCLUSION

3D Printing is the method of converting virtual 3D models into


physical model. After the arrival of 3D Printing futurist predicted that
wed soon see them in every home. In future consumers will
probably make what they want at home with their own 3D Printers. If
some want a latest fashion toy. They will buy the 3D file instead of
the product. One day we may have 3D Printer that use
nanotechnology to create products by depositing them atom by atom.
Simple machinery has been created at the atomic scale such as small
wheels, transistors and walking DNA. These could be the
precursors to more advanced custom manufacturing system.

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How Can We get employment with 3d Printing
Technology

Cost of 3d Printer is approx 3,00,000. That is too high. Till now


most of the civil engineer gives 2d diagram for constructing the
building. In that situation to give 3d model of 2d diagram then it
will give better impression on customer and no of customer of
civil engineer will be rapidly increase.
To create a design in pc can be print in 3d. It will give good
income.

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