1. Dr. Sean Jenkins Head of School Design & Applied Arts
Additive Manufacturing Technologies (3D Printing)
& 3D Scanning
Dr. Sean Jenkins
Head of School
Design & Applied Arts

2. 3D printing
History – in California – 3D Systems (worth $2 billion)
Process – the process of taking 3D digital data and creating a tangible object through additive processes utilising a layering technique.
Current systems - SLA, SLS, FDM, MJP, LOM
Materials
Organic
Ceramic
Polymeric
Metallic
Waxes
Tissue/cell
Sugars
Sand
Plaster
Silicon carbide
ABS
Nylon
PEEK
AU Loaded polyamide
Aluminium
Steel
Titanium
3D printing has been used in the product design process for over 20 years
Stereolithography (SLA) produces models by tracing a beam of UV light over a photosensitive pool of liquid.
Selective Laser Sintering (SLS) is similar to stereolithography replacing the UV light with a laser and a vat of liquid with a powdered base
Fused Deposition Modeling (FDM) creates models by heating and extruding a filament of plastic material.
Multi-Jet Printing (MJP) refers to the process of depositing liquid photopolymers onto a build surface using inkjet technology.
Laminated Object Manufacturing (LOM) machines cut and glue thousands of sheets of material together to form solids.
Electron Beam Melting. (EBM) a form of 3d Welding

3. 3D printing systems Powder Liquid Solid Liquid Printing
Break down 3d printing into 4 main categories

4. 3D printing systems Powder based – SLS/M and Powder
Selective Laser Sintering/Melting and Polymer Powder

5. 3D printing systems Liquid Based – SLA and DLP
Stereolithography and Direct Light Projection
Using a laser or digital light projection to cure a resin layer by layer

6. 3D printing systems Solid Based – FDM Fused Deposition Modelling
Extruding a plastic filament through a hot nozzle – functional plastic parts

7. 3D printing systems Liquid Printing Based Liquid Polymer Printing.
Printing a UV curable resin – high level of detail but expensive

8. 3D Printing Digital Workflow
Creation of CAD or Scan data
Translation of data to STL. File, ply. files or VRML. file
3D Printer software for orientation, position and support creation
Software slices model
Sent to Print
Removal for post processing
Post processing (infiltration, UV curing, bead blasting etc.)
Steps involved in the transfer of the digital design to a tangible 3D printed part.

9. Creation of Scan Data White Light Scanning / Photogrammetry
White Light Scanner – Artec EVA Scanner
Using a pattern of light to detect surface deformation to create the 3D data
Photogrammetry – 123D Catch, RECAP software
Using photos for multiple angles to triangulate a 3D image

10. Application of Scan Data
Fairing for Prosthetic -
Giving leg structure and bespoke prosthetics to people who have lost limbs
Cerebral Palsy Cast -
Traditional Method – 1 Hour to Cast; 6 months to make orthotic device
Scanning Method – 10 minutes to scan, 1/2 day transferring to 3D, 2 days to 3D print product

11. Creation of Scan Data MRI / CT / Ultrasound
Taking slices of data and combining them to create a 3D surface model
The surface model can then be transfered to a solid model and used for 3D printing

12. Application of Scan Data
Motorcycle Accident; facial reconstructive surgery – Creating guides for the surgery and also plates to fix the jaw bone to the skull
Surgeons in China have performed the world's first vertebra replacement surgery using customized vertebra created with a 3D printer.
Traditional – Pins are needed to support the neck and head for 3 months before the spine is fixed
3D Printing – The replacement vertebra section is an exact copy and so it will fit perfectly into place and because it is made from titanium, tissue will bond to it making sure that it is fixed.
Replacement elbow joint – The bone was printed out to make sure that the elbow joint would fit and to determine how the elbow joint would fix into place
This meant that the surgeons could practice the procedure before they operated on the patient

13. Application of Scan Data

14. Application of Scan Data

15. Industries using AM Technologies
FASHION
ARCHITECTURAL
MEDICAL
DENTAL
JEWELLERY
AEROSPACE
AUTOMOTIVE
ARTS AND CREATIVE INDUSTRIES

16. Why use 3D printing? Additive manufacturing process
Drivers – economic, environment, design freedom
No need for tooling, jigs and fixtures
Reduced capital investment (e.g. injection moulding)
Simplified supply chain – reduces lead time
Additive manufacturing Enables complete design freedom from traditional manufacturing methods
Cheap to make a design changes
Work along side traditional manufacturing processes. Can be used for jigs and fixtures during assembly of components.

17. Why use 3D printing? Embedding materials – electronic encapsulation
Geometric freedom – example : lattice structure developed for crumple zone on vehicles
Bespoke products – example: bio-medical applications, hearing aids, implants & replacements

18. Why use 3D printing? Life cycle and sustainability
reduces raw material, lighter weight components – example: honeycomb structure for aerospace industry saves fuel.
Reduced energy over traditional processes – AM produces ¼ of CO2 emissions compared to CNC
Scalable – example: “Contour Crafting” buildings

19. Latest 3D printing news WASP project
WASP PROJECT – Giant 3D printer for building houses

20. Latest 3D printing news 3D printing in glass
WASP PROJECT – Giant 3D printer for building houses

21. Latest 3D printing news NASA Mars habitat competition
WASP PROJECT – Giant 3D printer for building houses

22. Latest 3D printing news 3D printed sternum and ribs
Australia's CSIRO has added to the growing list of 3D-printed medical implants by designing and printing a replacement titanium sternum and rib cage for a 54-year-old cancer patient.
By using high resolution CT scans, Melbourne-based medical device company Anatomics, working with the patient's surgical team, was able to design an implant specifically customized to fit perfectly in the patient's chest. With the design in hand, the company turned to Lab 22, who printed the implant layer-by-layer using its AUD$1.3 million (US$920,000) Arcam electron beam metal 3D printer.

23. Latest 3D printing news 3D printed heart used to improve surgery
The patient's organs are scanned by an MRI machine.
They are then fed to a computer and the printer converts them into a 3D model.
Three dimensional models take around nine hours to be made on a specialist printer.
Each one costs around £400 to make.

24. 3D Software / Models Free Software Digital Libraries Cura GrabCAD.com
Meshmixer
Google Sketch Up
Meshlab
Scuptris
Blender
Fusion360
Digital Libraries
GrabCAD.com
youmagine.com
thingiverse.com
traceparts.com
3dcontentcentral.com

25. Useful Links TCTMagazine.Com N-e-r-v-o-u-s.Com Sculpteo.Com
Shapeways.Com
3ders.Org
Gizmag.Com/3d-printing
3dprint.Com

26. OPEN DAYS 2015: 7th Nov / 5th Dec
Product Design MDes | BA (Hons)
Product Design & Technology MDes | BSc (Hons)
Automotive & Transportation Design MDes | BA (Hons)