1. Basics of 3D Printing
Ville Kukko-Liedes

2. What is 3D Printing?

3. What is 3D Printing? Additive Manufacturing (AM):
Construction of physical objects directly from 3D CAD data – usually layer upon layer
(CAD = Computer Aided Design)

4. What is 3D Printing? Additive Manufacturing (AM):
Construction of physical objects directly from 3D CAD data – usually layer upon layer
(CAD = Computer Aided Design)

5. What is 3D Printing? Additive Manufacturing (AM):
Construction of physical objects directly from 3D CAD data – usually layer upon layer
As opposed to e.g. subtractive manufacturing (milling, turning etc.)
(CAD = Computer Aided Design)

6. What is 3D Printing? Additive Manufacturing (AM):
Construction of physical objects directly from 3D CAD data – usually layer upon layer
As opposed to e.g. subtractive manufacturing (milling, turning etc.)
(CAD = Computer Aided Design)

7. Principle
Stacking two-dimensional layers to form three-dimensional objects
Producing 2D layers is relatively simple
Parts usually need to be supported from below

8. “Slicing” to multiple layers,
Principle
STL file – From CAD,
3D-scan, etc.
“Slicing” to multiple layers,
toolpath
calculated for each
Part production
using calculated
paths

11. Uses: Rapid Prototyping
The original and still much used application of 3D printing
Commercialized in the 80s
(SLA by 3D Systems)
Extremely popular in product development:
Fast testing of form, fit, function, ergonomics..
Accurate representation of intended material properties and function possible
Affordable and quick to produce prototypes provide early feedback
Fail faster to succeed earlier!

12. Uses: Rapid Manufacturing
Use of AM to produce end-use parts and products
Expansion during the last 13 years
From 4% (2003) to 35% (2014)
Result of process and material development & media hype
Notable in medical and aerospace industries
Medical: Personalized solutions
Aerospace: Weight optimization
Potential in multiple fields, but still restricted to low volume or customized production of high-end products
Lacking standards & false assumptions hinder adoption

13. Uses: Rapid Tooling Use of AM for indirect production:
Masters for sand & silicon casting
Lost wax casting
Printing sand, metal & plastic molds
Fixtures for drilling
Jigs
Endless number of uses..
For both prototypes & end-use parts
Takes advantage of low investment cost, fast process, and AM introduced benefits such as contouring cooling channels in injection molds

14. DIY petrol motor for a surf board

15. Advantages of 3D Printing
– Freedom of design – complexity is free
Form optimization, pre-assembly, easy customization..
– No need for tooling
No cost from design changes & cheap small volume prod.
– No need for inventory
On-demand manufacturing, minimal investment,
– Fast lead times & responsiveness
Quick alteration in design to respond to customer needs
– Localized manufacturing
Manufacturing where needed, savings in logistics
– Wide material range – seamless transitions
Innovation potential with new opportunities
– Affordable low volume production
Price per piece constant regardless of production size

16. Freedom of design – No need to Design for Manufacturing & Assembly:
Instead Design for Functionality, Weight, Strength etc
– Minimize part count while optimizing topology
– Pre-built assemblies – minimize labor time & QC
– Customization without additional cost – Every part
can be different from the others, even in same batch

17. Design for AM – Case: bottle opener
If you’re gonna design for 3DP, might as well do it right
Here: less weight, less waste, looks cooler

18. Design for AM – Case: Buckle 68 grams
If you’re gonna design for 3DP, might as well do it right
Here: less weight, less waste, looks cooler
68 grams

19. Case: Boeing / F-18 air duct system re-design

20. Case: F-18 cooling air system
– Complete re-design for functionality & weight
– This unit: part reduction from 16 to 1
– Improved air flow
– No assembly required
– No tooling required
– Future improvements with minimal cost
– Spare parts on demand and on location

21. Role of 3D printing in the future
– Disruptive potential in manufacturing – happening already
3DP can change product design and manufacturing approaches drastically. Materials and processes are developed more for end-use production.
– Supply chain renewal – future possibility
Away from traditional towards more decentralized, on-demand, rapid manufacturing.
– Flourishing innovation around AM
New applications, AM techniques, & businesses emerge almost every day
– Will every home have a 3D Printer and traditional manufacturing will end?
No – maybe for occasional hobby or repair use
“Many have sewing machines, but don’t wear self made clothes”
In a brief summary, Direct digital manufacturing is in a rapidly evolving state.
It’s unique capabilities can support or even replace traditional methods in many different cases. Furthermore, the approach for product design changes drastically when designing for DDM.
There are still challenges to overcome and room improvement in many related fields, but the future of manufacturing seems very promising, with the addition of direct digital manufacturing.

22. Categories of 3D printing
Vat Photopolymerization
Powder Bed Fusion
Material Extrusion
Material Jetting
Binder Jetting
Sheet Lamination
Directed Energy Deposition

23. Categories of 3D printing
Vat Photopolymerization
Powder Bed Fusion
Material Extrusion
Material Jetting
Binder Jetting
Sheet Lamination
Directed Energy Deposition

24. SLS – Selective Laser Sintering

25. SLS – Selective Laser Sintering
Powder stock is joined by partial melting
The powder bed lowers with the part
New layer of powder is added and process repeated
Materials:
PA (6, 11, 12) (Nylon)
PA GF, CF (fibre composites)
PA-Al (30% Aluminium)
Manufacturers:
EOS, 3D Systems…

28. Categories of 3D printing
Vat Photopolymerization
Powder Bed Fusion
Material Extrusion
Material Jetting
Binder Jetting
Sheet Lamination
Directed Energy Deposition

29. SL – Stereolithography

30. SL – Stereolithography
UV laser cures resin
Build platform lowers with the part into the resin vat (or rises from it in some cases)
New layer of resin is cured and process repeated
Materials:
UV curable resins
Waxes
Ceramic
Manufacturers:
3D Systems, DWS, Lithoz,
+few hobbyist oriented

31. Formlabs Form1+ SL (Stereolithography) Liquid resins
Clear, White, Grey, Black, Flexible…
Build area: 125x125x165 mm
For precise small & medium size prints
User friendly, but needs careful handling – delicate optics inside
Slicing software: Preform
Mandatory post processing: clean + cure

34. Categories of 3D printing
Vat Photopolymerization
Powder Bed Fusion
Material Extrusion
Material Jetting
Binder Jetting
Sheet Lamination
Directed Energy Deposition

35. FDM – Fused Deposition Modeling

36. FDM – Fused Deposition Modeling
Molten plastic is extruded to form a layer of the part
Build platform lowers with the part and process repeats
Special support material with second nozzle – washed away
Materials:
ABS
Polycarbonate
Nylon
Manufacturers:
Stratasys, +multiple hobbyist oriented

37. NuNu FDM (Fused Deposition Modeling) Thermoplastics
ABS, PLA, Nylon (PA), HIPS
Build area: 180x200x300mm
For strong, medium sized prints
Needs mastering – multiple parameters to change
Slicing software: Cura
Optional post processing: support material removal

40. Accuracy
Method
Material
For
Tolerance (mm)
Layer Thickness (mm)
SLS PA
Functionality
+/- 0,15
(+/- 0,15%)
0,1
PA CF/GC
Hi durability
Wax
Casting SL
Clear
Appearance,
+/- 0,05-0,1
0,05-0,2
Flexible
Durability,
Appearance
FDM
ABS
Functionality,
prototyping
+/- 0,15-0,3
0,1-0,4 PC
3D prints are comparatively inaccurate dimensionally as well as geometrically
Parts can be machined where higher accuracy needed
Method can also be chosen based on material, price, availability, speed…

41. STL file format – triangulated mesh approximation
More triangles = more better (:

42. Orientation and support material

43. Design for FDM printer quick sheet
With low-resolution printers:

44. 3DP in Tooling
Ville Kukko-Liedes

45. Sandcasting
Printed
Finished
print
Cast
Finished
cast

46. Wax masters for precision casting

47. Core for Glass/Carbon-fiber layering

48. Vacuum forming cores

49. Injection molds printed with plastic

50. Masters for silicone casting

51. Tips for Finishing
Ville Kukko-Liedes

52. Inserts are better than self threading screws

53. ABS parts can be smoothed with acetone

54. Spray filler primer <3

55. Keep things modular – Screws over hot glue

56. Iterate!

57. 3D files to print CAD software – Create models yourself
3D scan an existing object– Modify or replicate as is
Download existing files – Free and commercial sites available

58. 3D files to print
CAD software – Create models yourself
3D scan an existing object– Modify or replicate as is
Download existing files – Free and commercial sites available
Sketchup, 123D Design, Autodesk Fusion, OpenSCAD, FreeCAD,
Commercial: Creo, Autocad, Catia, Maya, Rhino..

59. 3D files to print CAD software – Model yourself
3D scan an existing object – Modify or replicate as is
Download existing files – Free and commercial sites available

60. 3D files to print CAD software – Model yourself
3D scan an existing object– Modify or replicate as is
Download existing files – Designs available for free
Say you have your beatiful file now ready for printing. Hopefully ypu have learned by now that 3D printers don’t replicate everything to the point. This is a common misconception, which is understandable given how media likes to address 3D printing as a solution to solve all our problems. First of all, you know already that there are at least 3 different kinds of printers, right. So can you just go pick any one of them up print yourself a puppy? Well, no..

61. Break
Ville Kukko-Liedes
Thank u

62. Categories of 3D printing
Vat Photopolymerization
Powder Bed Fusion
Material Extrusion
Material Jetting
Binder Jetting
Sheet Lamination
Directed Energy Deposition

63. Categories of 3D printing
Vat Photopolymerization
Powder Bed Fusion
Material Extrusion
Material Jetting
Binder Jetting
Sheet Lamination
Directed Energy Deposition

64. SLM – Selective Laser Melting

65. SLM – Selective Laser Melting & Binder coated powder SLS
Powder stock is joined by laser melting
The powder bed lowers with the part
New layer of powder is added and process repeated
A lot of supports needed in direct melting!
Materials:
Two component (binder coated base)
Single component:
Ti6Al4V, 17-4 / 15-5 Stainless, Cobalt chromium, maraging
Uses: Molds, small series, prototyping in metal

68. Categories of 3D printing
Vat Photopolymerization
Powder Bed Fusion
Material Extrusion
Material Jetting
Binder Jetting
Sheet Lamination
Directed Energy Deposition

69. 3DP – Binder Jetting

70. 3DP – Binder Jetting Powder stock is joined by deposited binder
The powder bed lowers with the part
New layer of powder is added and process repeated
Materials:
Ceramic, composite, Glass, Metal, Plastic..
Color printers available
Usually fragile before post processing
Uses: Visuals, cores & molds, casting patterns

72. Full color sandstone + binder - Shapeways

73. Categories of 3D printing
Vat Photopolymerization
Powder Bed Fusion
Material Extrusion
Material Jetting
Binder Jetting
Sheet Lamination
Directed Energy Deposition

74. LOM – Laminated Object Manufacturing

75. LOM – Laminated Object Manufacturing
Sheet is joined to the previous part
Layer shape is cut into sheet
Platform lowers and process repeats
Materials:
Paper, plastic, metal
Color printers available
Not accurate with paper or metal
Laborious manual support removal
Uses: Visual aids, metal structures with internal sensors

77. Categories of 3D printing
Vat Photopolymerization
Powder Bed Fusion
Material Extrusion
Material Jetting
Binder Jetting
Sheet Lamination
Directed Energy Deposition

78. DED – Directed Energy Deposition
Sheet is joined to the previous part
Layer shape is cut into sheet
Platform lowers and process repeats
Materials:
Paper, plastic, metal
Color printers available
Not accurate with paper or metal
Laborious manual support removal
Uses: Visual aids, metal structures with internal sensors

79. DED – Directed Energy Deposition also LENS – Laser Engineered Net Shaping
Inert shielding gas jet deposits pwder that is molten to the part with laser
Platform moves, while nozzle is usually stationary
Materials:
Metal
Not very accurate ”net shaping”
Features machined
Combined DED + CNC exists!
Uses: Repairs

80. Categories of 3D printing
Vat Photopolymerization
Powder Bed Fusion
Material Extrusion
Material Jetting
Binder Jetting
Sheet Lamination
Directed Energy Deposition

81. Material jetting

82. Material jetting
Printhead (just like in inkjets) deposits droplets of resin that is cured instantly with UV
Platform moves down, process repeats
Materials:
Resins, various simulated plastic & rubber
Highly accurate
Multiple material properties, even smoothly changing
Uses: High end visual aids & function test

84. Links to videos Kinematics Dress by Nervous System
SLS Selective Laser Sintering
SLA Stereolithography
Binder Jetting metals
LOM - Mcor Paper Printer
MORI Hybrid 3DP-CNC
Material Jetting – Stratasys J750

85. Thank you
Ville Kukko-Liedes
Thank u