What is 3D printing and how does it work?
3D printing, also referred to as additive manufacturing, refers to the process of creation of a physical object from a digital design. It involves the synthesis of a three-dimensional object through the formation of successive layers under the control of a computer to create an object. The objects created from 3D printing can be of any geometry or shape and are created by the use of digital model data from either a 3D model or another electronic source of data for example files created from computer-aided design programs (Baird 2016, p. 66).
During the process of printing, the 3D printer starts usually begins at the bottom of the design and continuously build up successive layers of the material until the object is completed (Kurman 2013, p. 177). There is a wide range of 3D printing technologies and materials available for usage in different fields of which all are based on the same principle- the turning of a digital model into a solid three-dimensional physical object through the addition of material layer by layer. A 3D printer is composed of such parts as printer bed, bed surface, filament, extruder, gears, hot end, fans, and nozzles among other mechanical components.
The 3D extruder is the part of the printer from which a material which is either in liquid or semi-liquid form is ejected to deposit it in successive layers contained within the 3D printing volume (Bennett 2009, p. 89). It achieves this functionality by taking the filament from the coil and delivering it precisely to the surface of the base by the implemented settings which is read by the printer from the GCODE file thereby generating layers of the print. In some circumstances, extruders only deposit a bonding agent that is useful in the solidification of a material which was originally in powder form.
Depending on the type of the printer, extruders are composed of various components with characteristics which are unique to the printer in question. It is important to note that it is possible to change and adapt the extruder and electronics depending on the printer. Some of the components of a printer include driver gear, stepper motor, reduction gear, nozzle, hot-end, and thermistor. The stepper motor serves to push the filament to the nozzle from the coil to generate each of the layers during the printing process. The action of the motor is checked by the electronic of the printer, and it rotates in very short steps to ensure delivery of the exact amount of material needed to form the layers (Cline 2014, p. 102).
Components of a 3D printing extruder
The hot-end is involved in the heating and melting of the filament to ensure it liquefies to the required level that can enable it to go through the nozzle of the extruder. It is in the shape of a vertical tube through which filaments pass while still in the solid state. Heating of the filament takes place from the outside as it passes so that the high temperature reaches the interior resulting in a positive effect on the filament.
The drive gear is attached to the axis of the stepper motor like a staggered or groomed rim pulley, and its role is to apply traction that pushes the filament as the stepper motor rotates. The reduction gear also called wade system is a bigger gear used to increase the force applied to the filament. This gear may either make direct contact with the filament or not. The thermistor measures the temperature of the printer during operation and relays the information to the control system (Horne 2014, p. 324). This ensures there is correct management of the temperature since it is at this temperature that the filament leaves the nozzle.
The nozzle is conical in shape with one of the faces wider than the other one. Hot materials enter and accumulate through the wider face thereby leading to correct maintenance of its heat before leaving through the narrow opening. The diameter of the opening varies from one printer to another and is 0.4mm in Prusa i3 Hephestos and Wit box printers.
The extruder is found in 3d FFF or FDM printers as well important in the operation of machines that use polyjet technologies, binder jetting or even 3D Systems’ CPX machines (Cerda 2014, p. 421). These are some of the additive manufacturing machines which require depositing of materials before transformation either through changing the chemical properties as for the case of Polyjet or adding to it a bonding agent.
For FFF/ FDM printers: The extruder of an FDM printer is the region that extrudes the plastics filament in the form of liquid and deposits it on the printing surface by adding the successive layers. The head is made of such parts as a motor that drives the plastic filament and the nozzle that extrudes the plastic. With technological advancements, some FFF/FDM printers are fitted with two extruders that enable simultaneous printing of two materials that can produce two distinct colors of the 3D prints.
Types of 3D printing extruders: Bowden vs direct extrusion
3D printing extruders extrude in two forms i.e. Bowden extrusion and direct extrusion. In direct extrusion, the filament is pulled from the motor through the hot-end and straight to the nozzle. The extruder comes out as one part which can be detached and more compact. Direct extrusion has a number of advantages among them it is a compact extruder, it is completely detachable, and it allows for easy checking of any damages or resolution of jam. On the other side, its main disadvantage is the heavy weight (Horvath 2014, p. 187). The x and y-axes are affected by the heavy weight of the set.
For the case of Bowden extrusion, the filament reaches the coil the same way it does in direct extrusion with the difference being that the hot-end is separated from the motor and the filament taken to the x-axis carriage via a flexible pipeline. With such an arrangement, there is less weight on the x-axis since the motor is the only thing on it. At the same time, the x-axis is able to move better comparatively to direct extrusion as it carries less weight. It is also possible to reduce the size of the hot-end since it’s only used on the carriage. It is therefore possible to mount the relatively heavy extruder set and the motor onto the frame of the printer instead of on the carriage which is moving.
Bowden extrusion is more complicated to build and maintain, more likely to overflow as and very sensitive to errors. Either of the extruders fulfills the intended purposes as they both correctly extrude and place the material in order to build the object.
Regardless of the type and technology used in the 3D printer, the mode of operation of the extruder is basically similar (Horvath 2014, p. 211). The drive gear pushes the filament down and into the hot end. With the high temperature of the extruder, the heat flows up the column and softens the filament, which is not recommended. The avert this situation; the fans are used which flow cold air over the heat sink which deflects the heat away from the upper regions of the column while the filament stays rigid. The molten filament is pushed down by the rigid filament thereby creating a force which makes the filament to extrude out of the nozzle. The 3D printing would not work without the force applied on the molten filament (Hood-Daniel 2011, p. 161).
Advantages and disadvantages of Bowden and direct extruders
The head extruder in the link is extruded using Bowden extrusion form thus a Bowden extruder. A tube extends from the body of the extruder to the hot end as opposed to the extruder being directly attached to the hot end. The filament of the extruder which is o.4mm wide is tied by a meter long tube and moves through it to the hot end. The extruder is a direct drive Bowden extruder that runs 1.75mm filament. This extruder has a light weight riding on the hot end carriage system thus able to not only move but also print faster, more precisely, more accurately, than a direct extruder. The extruder is sold at $18.50 and free shipping is done on orders more than $35 of the same commodity.
Solid works is a program used to model solid objects by using parametric feature-based approach in the creation of the models and assemblies. The program is usually written on Parasolid-kernel (Murray 2000, p. 154). In the context of solid works program, parameters are limits of the values which determine the geometry or the shape of the model. These parameters can be either numeric values or geometric parameters and the numeric parameters are normally associated with each other using mathematical relations making them able to capture the intent of the design. The design intent, in this case, refers to how the model would respond to updates and changes as illustrated by the creator.
To build a model in solid work program, one has to start with a 2D sketch which consists of geometry including conics, points, arcs, splines and lines. The 2D sketch is dimensioned to specify the location and the size of the geometry and which mathematical relations are used to define such attributes as concentricity, parallelism, tangency and perpendicularity depending on the geometric features of the model (Matamua 2015, p. 230). The nature of the parameters solid works mean the geometry of the model is driven by the relations and dimensions rather than the other way round. These dimensions can either be controlled independently or by use of parametric relationships outside or inside the sketch.
For the case of an assembly, mates form the analog to sketch relations. Assembly relations outline the equivalent relationships with regard to the components or the individual parts thus allowing easy construction of the assemblies (Fulkerson 2015, p. 251). Solid works have additional features for mating such as gear and cam follower components that enhance accurate reproduction of rotational movement of the actual gear train by the modeled gear assemblies. Once the models have been drawn, the views can be generated automatically from the solid model, and it is possible to add dimensions, notes and tolerances to the drawings as needed that would make it easier to understand.
Introduction to SolidWorks Program and its features
The attached design picture was done with Solid Works program exhibit both parallelism and perpendicularity in the design. There is base of the model is supporting another cuboid that is lying parallel to it. The pillars on either side of the base of the model touch the base at a right angle thereby illustrating perpendicularity in its geometry. The geometry of the model exhibit such characteristics as point and lines which can be seen at the edges d the model. The model is not dimensioned thus giving a rough idea of what the actual design would look like (Planchard 2017, p. 378).
Mach3 program is software that turns a computer into a 4-Axis CNC controller for machining. Through mach3, it is possible to import parts or design them into Bob CAD-CAM as well as generate the tool path. Mach3 program is essential in industrial engineering as allows for easy machining and offers a variety of CNC control functionality (Langdon 2009, p. 620). The program works well with other programs hence making it possible to import DXF files and generate G-Code that can fully be customizable. It has wide applications ranging from Plasma Cutters, CNC Routers, Lasers, Lathers besides Milling Machines.
Mach3 program can be used in 3D printers. In this case, the way in which the extruder controls heating element using the dimmer switch is very vital and helpful. The extruder is set up on the 4th axis stepper drive then tuned to produce 1-inch filament movement. KisSlicer handles the slicing after which the corresponding Gcode of the program runs. The process revolves around heating the extruder, slicing a file and running the code during which the motor in tuned for A. in the case of massive and bigger machines, the extruder is hung off toward the spindle, after which the part is printed before bringing back the spindle (Overby 2010, p. 258)
The attached pictures on Mach3 programs are informative on where the software is applicable and how it operates. The program operates on a computer connected to a 4C circuit board which must be connected to stepper motors to enhance control of each of the motors of the computer (Horvath 2014, p. 188). Still, the software has a variety of add-ons and exist in various versions. Upon being downloaded, the program has step by step procedures that must be observed to ensure successful installation just like any other programs. For Mach3 program, the initial step is to configure the program by adjusting both the Ports and Pins to ascertain that the computer communicates with the motors. The next configuration step is to enable the 3 axis which is done with the possibility of 4 more axes should there need be. From this step, there is the third procedure which is involves limit switches and inputs. The inputs should be enabled in case they are installed on the machine. They should as well be connected to the correct pin number.
The final step in installing the program is to disable the emergency stop input. This input has to be disabled even though it is not able to detect physical input and is usually turned on manually each time a new project is to be started. The program is then tested upon successful installation where it is used to test the motors through jogging (Petrova 2014, p. 311). A programming language, G-code, is used in the determination of the path which the machine will take as well at its speed of motion along the identified path. G-code program can be put manually or be loaded directly into the software as a project file.
A wide range of 3D printing materials is available for use depending on the nature of the underlying task. Among the available materials include ABS, PLA, and Polyamide resin among other printing materials. PLA (Polylactic Acid) is one of the green printing materials and is best in printing hobbyists in 3D printer filament. Among its features are slight flexibility, printing temperature range of between 180 and 22?C (Shergill 2012, p. 155). Being an organic product, PLA is non-toxic and has a pleasant sweet smell.
Among the technical specifications of PLA are a density of 1.24g/cm3, an auto ignition temperature, a wall thickness range of 1 to 2mm, a melting temperature of about 155?C and a glass transition temperature of about 50?C (Vlack 2006, p. 425). Polylactic Acid is available in varieties of blends such as bamboo and wood. Due to its ability to absorb water from the air, PLA printing materials should be stored in vacuums to ensure maintenance of the quality of the material.
Acrylonitrile Butadiene Styrene (ABS) is a petroleum product, very resistant to high temperatures making it suitable for most of the applications in the real world. Among its features are a variety of colors making it more popular among users, mechanical strength hence longer lifespan of the model. Shiny, glossy look upon being processed with acetone vapor since acetone vapor is able to melt the upper layer of the printed object resulting into a smooth and shiny model (Santos 2004, p. 268). On the other hand, ABS is a no biodegradable and toxic substance that emits poisonous fumes and gases when burnt at high temperatures. Still, the material releases an awful smell when burnt.
The technical specifications of this material include a density of 1.05mg/m3, 200?C melting temperature, an auto ignition temperature and glass transition temperature of about 395?C and 100?C respectively. Still, ABS works with a wall thickness range of 1mm to 2.5mm. Just like PLA, ABS can absorb water from the air hence has to be stored in a vacuum to ensure it is not degraded by moisture which would, in turn, erode the quality of the prints (Shergill 2012, p. 106).
Polyamide (nylon) is one of the strongest and most durable synthetic polymers with a translucent, silky finish (Rothschild 2014, p. 65). This printing material is also called white plastic. Flexibility, natural white color and ability to be painted in any color are among its features. It is possible to be smoothened despite the rough texture. Bridge Nylon, Taulman 645 and Taulman 618 are some of the most commonly used types of nylon in 3D printing. Concerning the technical specifications, the material is 1mm wall thickness, melting, auto ignition and glass transition temperatures of 214?C, 343?C, and 68.2?C respectively.
Resin is yet another 3D printing material considered to deliver the highest quality. This is due to its properties such as transparency, stiffness, and hardness hence suitable for models that which require smooth surfaces and high details. Resins material is ideal for very accurate models that have limited functionality.
Polyethylene Terephthalates is said to be a better choice of material than ABS. This is because of its strength and flexibility. With its glossy finish, it has become very suitable for use in printing wearable and phone cases. PET is recyclable and does not emit toxic fumes at high temperatures. It has a print range temperature of between 212?C and 224?C and is available in ranges of colors thereby giving durable models of objects (Horne 2014, p. 397).
Blue tape painting material: This is a material that has found its application IN 3D printing since time memorial. Blue tape painter has a number of features that are responsible for its continued application as a painting material in 3D printing. Some of these features are as discussed: excellent coverage of the build platform. The tape is made in such a way that it is to stick down the platform and also very easy to remove making its application on a build plate a very simple task (FIS 2009, p. 162). The only point of challenge is lining up two strips which are needed to cover the build platform fully, but this is overcome by the ease of sticking and removal of the tape.
Surface quality: The surface of blue painter’s tape has the same texture as that of the paper hence enhancing the high quality finish. Despite the rough texture of the rape, it is durable and usable over and again before it is replaced. This aids in reducing the budgetary allocation on the printing tape. Still, blue painting material adheres excellently to the model. The rough texture helps in achieving this property as it provides some force onto which the model can bond. Blue painter’s tape holds the model components together for a relatively longer time (Bennett 2009, p. 420).
In summary on blue tape painting material, it is one of the best choices of painting material due to its low cost and ease of use. The tape can as well be used to generate smooth surface prints especially upon smoothening of the surface. Using blue tape painting materials save on time as quality time is present making the models as opposed to spending a lot of time preparing the materials to use in making the models (Reyner 2017, p. 154). The material takes minimum time to apply and remove and also sticks so well to models.
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