3D- Printing and Design

Dr. S.V. Satya Prasad,

Assistant Professor
Department of ME
 Types of CAD data Files
1. Native CAD File Formats: These are specific to the CAD software that created them.

• .DWG (Drawing): Native format for AutoCAD; widely used for 2D and 3D drawings.

• .DWT (Drawing Template): AutoCAD drawing templates.

• .DXF (Drawing Exchange Format): AutoCAD’s open format for data exchange between CAD systems

• .SLDPRT (SolidWorks Part): Used in SolidWorks to store part files.

• .SLDASM (SolidWorks Assembly): Stores assembly files in SolidWorks.

• .PRT (Part File): Used by NX, Creo, and other systems for 3D parts.

• .ASM (Assembly File): For assemblies in Creo, NX, etc.

• .CATPart / .CATProduct: Native files for CATIA parts and assemblies.

• .IPT / .IAM: Autodesk Inventor part and assembly files.

 Types of CAD data Files
2. Neutral or Exchange File Formats: These are used for sharing data between different CAD systems.

•.STEP / .STP (Standard for the Exchange of Product Data): Widely used for 3D model exchange.

•.IGES / .IGS (Initial Graphics Exchange Specification): Used for 2D and 3D model data exchange.

•.STL (Stereolithography): Common in 3D printing; stores surface geometry.

•.OBJ: Stores 3D geometry and material information; used in modelling and animation.

•.3DS: Autodesk 3D Studio format used in graphics and animation.

•.X_T / .X_B: Parasolid files used for sharing precise 3D data.

•.VRML / .WRL: Used for 3D web graphics and simulations.

 Types of CAD data Files
3. Drawing and Document Formats: For 2D representation or documentation.

•.PDF: Common for sharing 2D drawings or technical documents.

•.SVG (Scalable Vector Graphics): Used for 2D vector drawings on the web.

•.PLT (Plotter File): Used for plotting CAD drawings.

•.CGM (Computer Graphics Metafile): Standard for 2D graphics, often used in technical illustration.
 CAD MODEL
PREPARATION
Importance of CAD Modelling.
 Lattice Generation
 Lattice Analysis
 Tray Configuration
 Connection to 3D Printers
 Topology Optimization
 Engineering content
 Realism
 Usability and user interface
 Speed
 Accuracy
 CAD MODEL PREPARATION... Contd..

Factors required to prepare CAD Model for Additive Manufacturing.

 Tolerance optimization for mating parts
 Maintaining Resolution
 Resizing holes
 Water tight geometry
 Minimizing use of support material
 Balancing Part density and strength.
 ...
Part Orientation Introduction
Part Orientation Introduction...
IMPORTANCE OF PART ORIENTATION
• Part accuracy

• Build time

• Part strength

• Support Structures

• Surface finish
Part Orientation by
process
 Purpose of Part
Orientation
Finding the best suitable part orientation helps

achieving:
the shortest build time ie minimizing the number of

layers and part height

 the minimal amount of supports

an easy access to supports so that they can be easily

removed
 SUPPORT
STRUCTURES
What are Support Structures
 Used with almost all 3D printing technologies, support structures help to ensure the printability of a part during

the 3D printing process.

Support structures have several functions:

support the part in case of overhangs,
strengthen and fix the part to the building platform
 conduct excess heat away
prevent warping or complete build failure.
SUPPORT STRUCTURES..
Contd.
SUPPORT STRUCTURES.. Contd..
AM Processes and Support Structure Requirement
Downside of Supports
 Material costs

 Limited geometric freedom

 Extra time

 Additional post-processing

 Risk of damage
 Ways to Reduce Supports
1. Optimize Part Orientation
2. Design for Additive Manufacturing Use Lattice or Hollow Structures
3. Split the Model into Parts
4. Use Support-Efficient Materials or Techniques
MIMICS (Materialise Interactive Medical Image Control System)

•Mimics is an image processing software for 3D design and modeling, for medical, dental and additive
manufacturing industries.

•It is used to create 3D surface models from stacks of 2D image data. These 3D models can then be used for a
variety of engineering applications.

MIMICS is developed by Materialise NV, a Belgian company specialized in additive manufacturing software and
technology
 MAGICS (Materialise Advanced Geometry and Interactive Control
System)

•Magics is the industry-standard data and build preparation software, mainly used to prepare, repair, and
optimize STL files and other mesh formats before manufacturing.

•The focus is on speeding up all features and processes in an effort to help you save more time and energy than
ever before.

•The 3D nesting is approximately 30 times faster in the latest version, MAGICS 29 than in the previous version
of Magics enabling smooth flows and overall time gain.
Post Processing:
 Parts manufactured with 3D printing technologies usually require some degree of post-

production treatment.

 This important step of the 3D printing process is known as post-processing.

 In short, post-processing in 3D printing refers to any process or task that needs to be

performed on a printed part, or any technique used to further enhance the object.

 Think of it as a finishing touch to treat and refine parts that come out of a 3D printer.

 The options for post-processing 3D printed parts include removing support or excess material,

washing and curing, sanding or polishing a model to painting or colouring.

5 steps in post-processing
1.Cleaning

2.Fixing

3.Curing or hardening

4.Surface finishing

5.Colouring
1. Cleaning

a) Removing support material (FDM and Material Jetting)

There are two types of support material:

i) Insoluble Material

 Insoluble material is relatively strong and can

only be removed using tools as knives or pliers.
ii) Soluble Material

 The support structures can be dissolved in

water or with a chemical called Limonene.
 Examples of soluble materials are HIP (used as
a support with ABS material) and PVA (used as a
support with PLA material).
b) Powder removal (SLS and Powder Bed Fusion)

 Models printed using powder bed fusion (SLS are

fabricated using plastic or metal powders.
 Residues of powder can cling to or remain in the model, for
example in holes or more complex internal channels inside
the model.
 Excess powder can be removed manually but automated
solutions have arrived on the market that vibrate or rotate
to remove access powder.
 This 3D printing post-processing technique works like some
sort of a centrifuge rotating the part in all 3 dimensions.
c) Washing (SLA and Photopolymerization)

 Parts that are printed with SLA or other

photopolymerization can be easily cleaned
after printing.
 Two companies added post-processing
washing machines that are seamlessly
integrated in their print process line up.
 Form Labs added The Form Wash which uses
isopropyl alcohol (IPA) to clean the parts.

 Carbon developed the Smart Part

Washer machine to do the cleaning
2. Fixing:

Sometimes small repairs are needed to fill small holes or

cracks or even to attach parts that have been printed
separately.

a) Filling

When fillers and hardeners are used to repair unwanted

holes or cracks in the printed object.
b) Glueing and welding

Used when separately printed parts need to be

attached together.

ABS prints can be welded or glued together using

acetone.
3. Curing:

Formlabs and Carbon have added

curing using UV light to their
printing process (SLA and CLIP
respectively, both
Photopolymerisation processes).
After the model has been printed
special curing machines heat the
model to bring the part to its
optimal mechanical properties.
4. Surface Finishing:

a) Sanding

Layer lines or touch-points where support structure

was attached to the model can be removed by
carefully sanding the surface of the model, using
sanding paper with varying grit: from low to high for
finishing.
Aside from being labour intensive, manual sanding
can create inconsistent results. With automated
polishing, this can be avoided.
Layer lines are particularly visible on 3D models
produced using layering techniques (like FDM).
b) Vapour or Chemical Smoothing

Sometimes chemicals are used to smoothen the model

surface. The vapours react with the outer layer of the
object.
The layer lines are melt away, leaving a smooth outer
layer while giving the model a glossy look.
For models printed with PLA and ABS the acetone is
often used, or the chemical agent Tetrahydrofuran
(THF).
The problem with this technique is that is cannot be
controlled: small features can be melted off that should
remain.
5. Colouring:

In some cases, 3D models can be printed using coloured

material and with multi-material printing (multi-)
coloured prints can be made. But one can also opt for
colouring during the post-processing phase.

Coating and painting

Parts that need colouring would ideally be printed

using white material.
Before the model is painted a layer of primer is
usually applied. Painting can be done manually using
a brush or spray.
There are machines that automate spraying.