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3D Printing Technology and Its Application in Industrial Manufacturing

April 2020
IOP Conference Series Materials Science and Engineering 782(2):022065

DOI:10.1088/1757-899X/782/2/022065

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3D printing technology is widely used in industrial manufacturing, medical biology, and cultural creativity because of its direct molding.Based on the characteristics and advantages of 3D printing technology, this paper takes the 3D printing technology molding principle and process flow as the research object, and analyzes 3D Application of printing technology in automotive manufacturing, aerospace and electrical industries.

Process flow chart of 3D printing technology

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3D Printing Technology and Its Application in Industrial Manufacturing

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EMCEME 2019

IOP Conf. Series: Materials Science and Engineering 782 (2020) 022065

IOP Publishing

doi:10.1088/1757-899X/782/2/022065

3D Printing Technology and Its Application in Industrial

Manufacturing

Botao Hao* and Guomin Lin

Xijing University of Mechanical Engineering, Xi’an, China

*Corresponding author e-mail: 949724965@qq.com

Abstract. 3D printing technology is widely used in industrial manufacturing, medical

biology, and cultural creativity because of its direct molding.Based on the

characteristics and advantages of 3D printing technology, this paper takes the 3D

printing technology molding principle and process flow as the research object, and

analyzes 3D Application of printing technology in automotive manufacturing,

aerospace and electrical industries.

1. Introduction

3D printing technology, also known as rapid prototyping and additive manufacturing, is a technology

based on three-dimensional models that uses materials such as plastics, metal powders, and adhesive

materials to build materials layer by layer. The traditional "debarring processing" uses cutting, cutting,

turning, milling, grinding and other processes to remove the unnecessary parts of the material, and

waste materials. When the shape of the workpiece is complex, it is often difficult to process and even

unable to process. 3D printing technology is stacked layer by layer, no tools and molds are needed, the

production cycle is greatly reduced, and structures that are difficult to process or cannot be processed

by traditional processes can be manufactured, and the material utilization rate is high. 3D printer

technology can produce products with any complex shape, without having to consider processing

problems, and solve the design and manufacturing problems of complex parts. Therefore, 3D printing

technology is a very important production method in industrial manufacturing [1].

2. Status of 3D printer technology

2.1. Foreign status

The United States and Europe have always been the leaders in the research, development and

application of 3D printing technology. The United States is the global leader in 3D printing technology

and application, while Europe also attaches great importance to the research, development and

application of 3D printing technology. At present, in developed countries in Europe and the United

States, 3D printing technology has initially formed a successful business model. For example, in the

consumer electronics industry, aviation industry, automobile manufacturing and other fields, 3D

printing technology can produce small batch customized parts with low cost and high efficiency, and

complete complex and sophisticated manufacturing [2]. Currently, in the global 3D printer industry,

whether the system (equipment) development, production or marketing, the United States is the

world's leading position. Two companies, 3D Systems and Sratays, have the majority of the market.

EMCEME 2019

IOP Conf. Series: Materials Science and Engineering 782 (2020) 022065

IOP Publishing

doi:10.1088/1757-899X/782/2/022065

2.2. Domestic status

Domestic 3D technology emerged in the late 1980s. In 1988, professor yan yongnian, a pioneer of

rapid prototyping technology in China, set up the laser rapid prototyping center of Tsinghua

University. Xi 'an jiaotong university has independently developed a variety of 3D printer nozzlers,

developed advanced curing system and supporting materials, and its printing accuracy can reach

0.1mm. The University of Science and technology of China has developed a jet device to deal with the

combination of multiple nozzles, which is expected to be applied in the fields of micro-manufacturing

and optoelectronic devices. Some of the domestic technology in the world's advanced level. The

technology of laser direct processing of metal has developed rapidly and can meet the requirements of

mechanical properties of special parts. Laser direct manufacturing technology for forming large

titanium alloy structure parts has the characteristics of short flow and low cost, which has wide

application prospects [3].

3. Process flow of 3D printing technology

The common 3D printing technology types include SLA (Stereolithography) three-dimensional

engraving technology; FDM (Fused Deposition Modeling) selective cladding of filamentous material;

SLS (Selected Laser Sintering) selective Sintering of powder materials; LOM (Laminated Object

Manufacturing); 3D Printing powder selective bonding technology, etc. The following are the

principles and characteristics of common 3D printing technologies, as shown in table 1.

Table 1. Principles and characteristics of common 3D printing technologies

Types principle material advantage Disadvantage

SLA UV laser Solidify Photosensitive

resin

Excellent

performance rough surface

FDM

High-temperature

nozzle

Melt extrusion

Plastic wire easy to use Poor accuracy

SLS Laser melting

sintering powder Excellent

performance rough surface

LOM Laser cut hot melt

adhesive bonding Foil large size Poor performance

3DP Nozzle adhesive powder Color printing Intensity

difference

The process flow of 3D printing technology is shown in Figure 1. It mainly includes four steps,

which are three-dimensional model establishment, preprocessing, prototyping and post-processing.

Figure 1. Process flow chart of 3D printing technology

EMCEME 2019

IOP Conf. Series: Materials Science and Engineering 782 (2020) 022065

IOP Publishing

doi:10.1088/1757-899X/782/2/022065

(1)Three dimensional model: 3d CAD data model directly drives the additive manufacturing

system.Therefore, the first process of additive manufacturing process should be to design the 3d CAD

data model of the product. At present, the data file format widely accepted by various software is STL.

Therefore, a large number of small triangle planes should be used to approximate the original solid

model and approximate the original 3d data model.

(2) Preprocessing: select the appropriate molding direction and cut the 3d model with a series of

planes with the same spacing along the direction of the molding height, so as to obtain the 2d contour

information of the cutting layer. The smaller the spacing height, the higher the molding accuracy and

the longer the molding time, and the lower the molding efficiency.

(3) Prototyping: Using a forming head, under the control of a computer, according to the contour

information of the cross-section of each layer, a two-dimensional scanning movement is performed,

and the materials of each layer are stacked and bonded to obtain the final three-dimensional solid. The

forming head can be a laser head or a nozzle.

(4) Post-treatment: The purpose of post-treatment includes improving the strength of the product

and reducing the surface roughness of the product. The process includes repairing, grinding, post-

curing, peeling, polishing, and coating.

4. Application of 3D printing technology in industrial manufacturing

4.1. Application of 3D printing technology in automobile manufacturing

3D printing technology application benefits Saddle is a significant industry for the automobile

manufacturing industry. Almost all famous car manufacturers in the world have earlier

cited 3D printing technology to assist the development of their new models, and have achieved

significant economic and time benefits [4].

The BMW Company in Germany uses 3D printing technology to improve the ergonomics of hand-

held assembly tools, improve productivity, worker comfort and process repeatability [5]. For example,

the installation handheld device of a certain model adopts an internal thin rib structure instead of the

original solid structure, and the mass is reduced by 1.3 kg, which improves the handheld comfort,

reduces the quality and improves its balance.

Hyundai Motor Company adopted the United States Stratasys company FDM 3D printing system

designed for inspection, evaluation and aerodynamic function test [6]. TaeSunByun, chief engineer of

Hyundai Motors' Automated Technology Department, said: "The accuracy and stability of the space is

crucial for design inspection. The FDM Maxum system using ABS engineering plastics meets these

two requirements. With a length of 1382mm, the maximum error of only 0.75mm [7].

4.2. 3D printing technology in the field of aerospace applications

Aerospace manufacturing field - generally single-piece small-lot production, expensive materials, high

product requirements, complex shapes, traditional manufacturing processes, high cost and long cycle

time [8]. Using 3D printing technology to make models for testing, direct or indirect production of

products has significant economic and time benefits. The more complex the product is, the more

advantageous it is. As shown in Figure 2.

EMCEME 2019

IOP Conf. Series: Materials Science and Engineering 782 (2020) 022065

IOP Publishing

doi:10.1088/1757-899X/782/2/022065

Figure 2. Advantages of 3D printing complex products

Aerospace parts are often complex systems operating in a limited space, the SLA model can be

used directly in the wind tunnel test, and the intake line can be assembled test, discussed

manufacturability evaluation, to determine the optimum rational production process. Through

auxiliary technology such as rapid investment casting and rapid sand casting, the single-piece, small-

lot production of special complex parts, such as turbines, blades, impellers, etc, and trial production

and testing of engine and other components.

Many parts of engines in the aerospace industry are made by precision casting. For high-precision

wood molds, the traditional process is extremely expensive and takes a long time to make [9]. Using

3D printing technology, it is possible to produce the master mold of investment casting directly from

3D CAD digital model, which significantly reduces the time and cost. In just a few hours, CAD digital

models can be used to produce low-cost and complex 3D printing master models for investment

casting [10].

4.3. 3D printing technology in the electrical industry applications

With the increase in consumption levels and the increasing number of consumers pursuing a

personalized lifestyle, the frequency of electrical product upgrades is increasing. Constantly improved

appearance design and structural changes caused by functional changes have made the rapid

production of electrical product shell parts and components have a wide market demand.

The first version of the plastic parts of the hair dryer, the development of new products is a key task.

The production of the first version of the sample can make the user intuitively understand the

designer's design concept and design intent, so that the hair dryer Eventual marketing. Many of the

plastic parts involved in the production of the first edition can be quickly

manufactured using 3D printing technology for evaluation, assembly and performance testing, greatly

reducing the development cycle and increasing the success rate of development.

5. Conclusion

According to the characteristics of 3d printing technology in industrial manufacturing, suitable for

complicated and difficult to machining materials component, do not need heavy forging industrial

infrastructure and mould, short design cycle, high material utilization, the unique advantages [11]. In

the field of industrial manufacturing shows the effect that cannot replace and broad application

prospect, become an international frontier research hotspot and important directions.

EMCEME 2019

IOP Conf. Series: Materials Science and Engineering 782 (2020) 022065

IOP Publishing

doi:10.1088/1757-899X/782/2/022065

References

[1] Li Fusheng . Talking about 3D printing technology and industrial development [J]. Science and

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Automation [J]. Modern Information Technology , 2019 (19): 175-176.

[3] Wei Dongsong . Application Research of 3D Printing Technology in Industrial

Design [J]. Industrial Design , 2018 (03): 121-122.

[4] Chen Peng . Application of 3D printing technology in automobile manufacturing [J]. Auto

Times , 2018 (11): 27-28.

[5] Jiao Keru , Xin Long . Research on the application of 3D printing technology in automobile

manufacturing [J]. Computer Products and Distribution , 2018 (04): 168.

[6] Liu Chunrong . Research on the application of 3D printing technology in the field of automobile

manufacturing and maintenance [J]. Times Automobile , 2019 (11): 127-128.

[7] Zhao Huajian , Yuan Yajun , Cai Zhengxing . Application of 3D printing technology in

packaging design of automobile parts [J]. Green Packaging , 2018 (09): 51-55.

[8] Liu Fei , Wang Wei, Li Jinyue, et al . Application of 3D printing technology in the development

of space vehicles [J]. Aerospace Manufacturing Technology , 2018 (06): 58-62.

[9] Cao Hongyi, Qi Xiang , Zhu Xiaotong . Application of 3D printing technology in aviation

maintenance [J]. Metal Processing ( Cold Working ), 2018 (09): 62-64.

[10] Li Chuantao . Application of 3D printing technology to aviation aluminum alloy thin-walled

parts [J]. Mechanical & Electrical Information , 2019 (15): 80-81.

[11] Yu Yongkun . Application and Analysis of 3D Printing Technology in Industrial Design

Innovation Strategy [J]. Modern Industrial Economy and Information Technology , 2019

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FUSED DEPOSITION MODELING IN 3D PRINTING

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May 2022

Bojan Stojcetovic

The term 3D printing in the original sense refers to the processes that sequentially place material on a stand with powder and nozzles. In recent times, the meaning of the term has expanded to include a wider range of techniques, such as processes based on extrusion and sintering. In a broader technical sense, the term "additive manufacturing" is used for 3D printing. Fused deposition modeling, or FDM 3D Printing, is a method of additive manufacturing where layers of materials are fused together in a pattern to create an object. The material is usually melted just past its glass transition temperature, and then extruded in a pattern next to or on top of previous extrusions, creating an object layer by layer. This paper presents a review of fused deposition modeling tehnology in 3D printing.

Path Planning of Autonomous 3-D Scanning and Reconstruction for Robotic Multi-Model Perception System

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Applying a three-dimensional (3-D) reconstruction from mapping-oriented offline modeling to intelligent agent-oriented environment understanding and real-world environment construction oriented to agent autonomous behavior has important research and application value. Using a scanner to scan objects is a common way to obtain a 3-D model. However, the existing scanning methods rely heavily on manual work, fail to meet efficiency requirements, and are not sufficiently compatible with scanning objects of different sizes. In this article, we propose a creative visual coverage path planning approach for the robotic multi-model perception system (RMMP) in a 3-D environment under photogrammetric constraints. To realize the 3-D scanning of real scenes automatically, we designed a new robotic multi-model perception system. To reduce the influence of image distortion and resolution loss in 3-D reconstruction, we set scanner-to-scene projective geometric constraints. To optimize the scanning efficiency, we proposed a novel path planning method under photogrammetric and kinematics constraints. Under the RMMP system, a constraints-satisfied coverage path could be generated, and the 3-D reconstruction from the images collected along the way was carried out. In this way, the autonomous planning of the pose of the end scanner in scanning tasks was effectively solved. Experimental results show that the RMMP-based 3-D visual coverage method can improve the efficiency and quality in 3-D reconstruction.

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Fused deposition modelling (FDM) is a material extrusion method of additive manufacturing where materials are extruded through a nozzle and joined together to create 3D printed objects. Most FDM systems allow you to adjust several process parameters. These include various travel speeds, layer height, cooling fan intensity and nozzle and build platform temperatures. In addition, in order to achieve better print quality, there are many software settings that can be used/modified and one of them are overhangs. Overhangs are specific geometrical parts of a 3D printed specimen. They are the shapes that extend outward, so they don't have direct support from the previously printed layer hence why they are challenging to print. This paper present the influence of the slope angle on overhang surface quality using a low-cost 3D printer, the Creality 10-S. 5 specimens were printed and the printed surface quality was measured with a EHEV1-200USB DIGITAL PEN camera.

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The technology of 3D printing represents the making of three-dimensional (3D) parts layer by layer directly from a computer-aided design (CAD) model file. The technology of 3D printing emerged as a flexible and powerful technique in the advanced manufacturing industry. Besides the previously stated industry, the technology became widespread in a great number of other fields. Even though 3D printing gives engineers and designers a possibility of a clear insight in the process of designing, the emphasis of many parameters, the possibility of easy and early detection of errors and their quick efficient correction, it is increasingly being used for making a variety of products. Besides conventional thermoplastics, the materials being used in 3D printing are ceramics, graphene-based materials as well as metals. This paper presents the overview of available technology types, the application and materials that are used for 3D printing in the machining industry.

Functionalized 4D-printed sensor systems

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Jan 2022

Additive manufacturing technologies such as screen, inkjet, and three-dimensional (3D) printing of various conductive, nonconductive, and specifically engineered materials can be beneficially employed to fabricate diverse electronic systems such as sensors, actuators, and batteries. By employing these technologies, such systems can be fabricated highly specialized and individualized while still being comparably inexpensive. The high degree of specialization has recently led to an increased aim to reduce system complexity while still achieving the desired functionality. To this end, 4D-printing is an advantageous approach since it results in systems that can be externally controlled through specific environmental stimuli (temperature, humidity, light, etc.) without the necessity of solid-state circuitry and control algorithms. This chapter deals with functionalized sensor systems based on additive fabrication technologies and their combinations. An outline of how these can be beneficially applied to robotics and wearable medical applications for human-device interfaces is given together with an outlook into the developments toward 4D-printing and promising future applications.

Preparation of Artificial Pavement Coarse Aggregate Using 3D Printing Technology

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Coarse aggregate is the main component of asphalt mixtures, and differences in its morphology directly impact road performance. The utilization of standard aggregates can benefit the standard design and performance improvement. In this study, 3D printing technology was adopted to prepare artificial aggregates with specific shapes for the purpose of making the properties of artificial aggregates to be similar to the properties of natural aggregates. Through a series of material experiments, the optimal cement-based material ratio for the preparation of high-strength artificial aggregates and corresponding manufacturing procedures have been determined. The performance of the artificial aggregates has been verified by comparing the physical and mechanical properties with those of natural aggregates. Results indicate that using 3D printing technology to generate the standard coarse aggregate is feasible, but its high cost in implementation cannot be ignored. The 3D shape of the artificial aggregate prepared by the grouting molding process has a good consistency with the natural aggregate, and the relative deviation of the overall macro-scale volume index of the artificial aggregate is within 4%. The average Los Angeles abrasion loss of artificial cement-based aggregate is 15.2%, which is higher than that of diabase aggregate, but significantly lower than that of granite aggregate and limestone aggregate. In a nutshell, 3D printed aggregates prepared using the optimized cement-based material ratio and corresponding manufacturing procedures have superior physical and mechanical performance, which provides technical support for the test standardization and engineering application of asphalt pavements.

A Review on Advanced Manufacturing for Hydrogen Storage Applications

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Hydrogen is a notoriously difficult substance to store yet has endless energy applications. Thus, the study of long-term hydrogen storage, and high-pressure bulk hydrogen storage have been the subject of much research in the last several years. To create a research path forward, it is important to know what research has already been done, and what is already known about hydrogen storage. In this review, several approaches to hydrogen storage are addressed, including high-pressure storage, cryogenic liquid hydrogen storage, and metal hydride absorption. Challenges and advantages are offered based on reported research findings. Since the project looks closely at advanced manufacturing, techniques for the same are outlined as well. There are seven main categories into which most rapid prototyping styles fall. Each is briefly explained and illustrated as well as some generally accepted advantages and drawbacks to each style. An overview of hydrogen adsorption on metal hydrides, carbon fibers, and carbon nanotubes are presented. The hydrogen storage capacities of these materials are discussed as well as the differing conditions in which the adsorption was performed under. Concepts regarding storage shape and materials accompanied by smaller-scale advanced manufacturing options for hydrogen storage are also presented.

Bacterial Biofilm Growth on 3D-Printed Materials

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Recent advances in 3D printing have led to a rise in the use of 3D printed materials in prosthetics and external medical devices. These devices, while inexpensive, have not been adequately studied for their ability to resist biofouling and biofilm buildup. Bacterial biofilms are a major cause of biofouling in the medical field and, therefore, hospital-acquired, and medical device infections. These surface-attached bacteria are highly recalcitrant to conventional antimicrobial agents and result in chronic infections. During the COVID-19 pandemic, the U.S. Food and Drug Administration and medical officials have considered 3D printed medical devices as alternatives to conventional devices, due to manufacturing shortages. This abundant use of 3D printed devices in the medical fields warrants studies to assess the ability of different microorganisms to attach and colonize to such surfaces. In this study, we describe methods to determine bacterial biofouling and biofilm formation on 3D printed materials. We explored the biofilm-forming ability of multiple opportunistic pathogens commonly found on the human body including Escherichia coli, Pseudomonas aeruginosa, and Staphylococcus aureus to colonize eight commonly used polylactic acid (PLA) polymers. Biofilm quantification, surface topography, digital optical microscopy, and 3D projections were employed to better understand the bacterial attachment to 3D printed surfaces. We found that biofilm formation depends on surface structure, hydrophobicity, and that there was a wide range of antimicrobial properties among the tested polymers. We compared our tested materials with commercially available antimicrobial PLA polymers.

Fracture Mechanics Performance of Through-Thickness Crack of Polymeric 3D Printed Components

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Jan 2021

This experimental study aims to explore the failure behavior of a pre- and post-cracked polymeric 3D printed components subjected to tensile mode. A set of through-thickness pre-cracked specimens of different cracks patterns and geometry was designed and implemented in the 3D printed parts. The specimens are then subjected to a tensile test mode. Besides, analogous intact samples were produced by 3D printing technology where the through-thickness post-cracks were created using laser cutting process of a geometry with cracks similar to those of the pre-cracked specimens. It has been observed that the pre-cracked samples initially introduced, and 3D printed cracked specimens have more resistance to fracture mechanics failure due to crack-bridging caused by the 3D printing filament profile around the crack profile. On the other hand, the samples with post-cracks made by laser cutting demonstrated a significant drop in the fracture failure resistance due to the interruption of the 3D printed filaments of the intact specimens. In conclusion, this study revealed that pre-cracked 3D printed components did not show the actual failure and fracture mechanics behavior. This is because the cracks could be introduced in the components after the additive manufacturing process during the service life and that would damage the 3D printed filament path of the components and, hence, will cause high-stress concentration that leads to unpredicted and fast failure.

Mechanical performance of three-dimensional printed sandwich composite with a high-flexible core

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P I MECH ENG L-J MAT

This paper aims to investigate experimentally and using finite element analysis the performance of using three-dimensional printing technology to produce a composite sandwich panel that is made of the high-flexible core as well as with high stiffness upper and lower surfaces made of a glass fiber reinforced composite filament. There are many advantages of using sandwich structures in many applications, especially the aerospace field, where the high stiffness to strength and the lightweight is the most preferred in such applications. The conventional manufacturing methods that are used to produce sandwich panels are limited to particular core geometry, whereas manufacturing a composite core is not possible by these traditional production methods. So by using additive manufacturing technology, it becomes more applicable to design a combination of different geometries and materials to achieve properties that have never been made before, especially combining flexibility and high energy absorption keeping high strength to failure. A central deflection to a length of 0.26 is observed within the elastic zone, a remarkable ratio in beams that reflects the three-dimensional printed sandwich beams’ capability with a highly flexible core to absorb energy that would open doors for many industrial applications that is attributed to the lowest flexural rigidity (167E-3Pa · m4) of the sandwich by using the TriHex infill pattern. In contrast, the Gyroid infill structure could afford the highest central load (0.264 kN). At the peak load applied on the sandwich beam, a maximum error of 5.4% is estimated by finite element analysis lower than the experimental values.

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3D printing technology is one additive manufacturing technology which involves mechanical, electronics, optics, materials and other disciplines. The domestic and foreign research status are introduced. The applications in the mechanical aspect are especially analyzed. The problems in the applications and the prospect are discussed at last.

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Rapid prototyping technology manufactures the product prototype can be generated directly from 3D CAD data and can be regenerated easily after the design was modified. This paper introduces the principle of rapid prototyping technology and the applications of rapid prototyping technology in automobile design, development and production. It is notable that the rapid prototyping technology is an effective tool to reduce the development cost of automobile products and shorten the development cycle.

Talking about 3D printing technology and industrial development [J]

Jan 2019
79

Fusheng

Li Fusheng. Talking about 3D printing technology and industrial development [J]. Science and Technology Innovation, 2019 (31): 79-80.

Application Research of 3D Printing Technology in Industrial Design [J]

Jan 2018
121

Dongsong

Wei Dongsong. Application Research of 3D Printing Technology in Industrial Design [J]. Industrial Design, 2018 (03): 121-122.

Research on the application of 3D printing technology in automobile manufacturing [J]

Jan 2018
168

Keru

Jiao Keru, Xin Long. Research on the application of 3D printing technology in automobile manufacturing [J]. Computer Products and Distribution, 2018 (04): 168.

Research on the application of 3D printing technology in the field of automobile manufacturing and maintenance [J]

Jan 2019
127

Chunrong

Liu Chunrong. Research on the application of 3D printing technology in the field of automobile manufacturing and maintenance [J]. Times Automobile, 2019 (11): 127-128.

Application of 3D printing technology in packaging design of automobile parts

Jan 2018
51-55

Zhao Huajian
Yuan Yajun
Cai Zhengxing

Zhao Huajian, Yuan Yajun, Cai Zhengxing. Application of 3D printing technology in packaging design of automobile parts [J]. Green Packaging, 2018 (09): 51-55.

Application of 3D printing technology in the development of space vehicles

Liu Fei
Wang Wei
Li Jinyue

Liu Fei, Wang Wei, Li Jinyue, et al. Application of 3D printing technology in the development of space vehicles [J].

Application of 3D printing technology in aviation maintenance

Jan 2018
62-64

Cao Hongyi
Qi Xiang
Zhu Xiaotong

Cao Hongyi, Qi Xiang, Zhu Xiaotong. Application of 3D printing technology in aviation maintenance [J]. Metal Processing ( Cold Working ), 2018 (09): 62-64.

Application of 3D printing technology to aviation aluminum alloy thin-walled parts [J]