3D printing of multilayer coating

Presented bySara Pakseresht

2016

• Three-dimensional (3D) printing is a manufacturing method in which objects are made by fusing or depositing materials—such as plastic, metal, ceramics, powders, liquids, or even living cells—in layers to produce a 3D object.

• It is an additive manufacturing technology.

• In a basic setup, the 3D printer first follows the instructions in the computer-aided design (CAD) file to build the foundation for the object, moving the printhead along the x-y plane. The printer then continues to follow the instructions, moving the printhead along the z-axis to build the object vertically layer by layer.

• In contrast with conventional printers, 3D printing has the potential to enable mass customisation of goods on a large scale.

History of 3D printing• 1984 Charles Hull invented 3D printing which he

described as stereolithography (STL) or the ‘printing’ of successive layers of material on top of each other to create a 3D object.

• Later 1990’s Other Companies developed 3D printer’s.

• 2005 Z Corp launched first high definition color 3D

printer.

Step2: The CAD file is exported to a 3D printing machine. Generated 3D CAD data are then processed and sliced into layers of equal thickness, each of which is the cross-section of the 3D model at a certain level.

Step1: (CAD file is created)

LAYER BY LAYER

Sliced data are imported into the additive manufacturing system to fabricate 3D objects layer-by-layer. In this fabrication process, layers are cumulated vertically and fused to form the final physical object.

The 3D printing technique should be accompanied by an appropriate material choice.

Step 3-Actual object

Post Process These are some treatments on 3D Printed objects after completing printing

process. It will bring strength, surface finishing, density to printed objects.

1 •Depowdering•Cleaning

2 •Coating

3 •Sintering•Infiltration

Powder • The material used for 3D printing is powdered as per requirement.• Additives can be used along with Powder to enhance printing. e.g: Lecithin, Graphites, Ceramics

Binders• Binder is a glue used to bind the powder together to produce required

shape.• Binder is selected with respect to the chemical and physical properties of

powder.• Binders can be organic(polyvinyls), inorganic (silica compounds), metal

salt(Copper Sulphate (For steel)), Solvents e.g: Chloroform used to bind polyesters and plastics, etc.

Application

• Using this technique to rapidly screen new potential therapeutic drugs on 3D printed patient tissue, greatly cutting production costs and time.

• There are many potential uses for 3D printing in medicine, including ophthalmology and repair or replace defective organs, such as kidneys, heart or skin.

• Electronic device application

• Polymer structure application

• Sensors

The first step is to scan the human skull with the helical CT unit in order to acquire a sliced image of the skull. The next step is to attach human cells onto the scaffold for subsequent tissue formation steps. (The precursor material for the printing process involves calcium phosphate.)

Types of 3D printing methods

• The type of 3D printing chosen for an application often depends on

the materials to be used and how the layers in the finished product

are bonded. The three most commonly used 3D printer technologies

are: selective laser sintering (SLS), Stereolithography (STL), and

fused deposition modeling (FDM).

SELECTIVE LASER SINTERING

• Selective laser sintering (SLS) is an additive manufacturing technique that uses a high power laser and was developed and patented in the mid-1980s.

• An SLS printer uses powdered material as the substrate for printing new

objects. A laser draws the shape of the object in the powder, fusing it together. Then a new layer of powder is laid down and the process repeats, building each layer, one by one, to form the object.

• Laser sintering can be used to create metal, plastic, and ceramic objects into a mass that has a desired 3-dimensional shape.

STEREOLITHOGRAPHY TECHNIQUES

• The stereolithography (STL) technique was developed by Hull in 1986 and was described in his patent “Apparatus for Production of Three-Dimensional Objects by Stereolithography”.

• Stereolithography is a technique of producing parts one layer at a time by curing a photoreactive resin with a UV laser or another similar power source. In addition to using a single-point laser, stereolithography can be performed with a digital micromirror-array device (DMD).

• After one layer is fabricated, the platform is lowered or raised to cumulate a new layer. The thickness of each layer is controlled by the distance between the surface of the platform and the liquid resin surface.

Fused deposition modeling (FDM) • Fused deposition modeling (FDM) is an additive manufacturing

technology commonly used for modeling, prototyping, and production applications.

Fused deposition modeling

3D Printing of Interdigitated Li-Ion Microbattery Architectures

• 3D printing can now be used to print lithium-ion microbatteries the size of a grain of sand. The printed microbatteries could supply electricity to tiny devices in fields from medicine to communications.

• For the first time in 2013, a research team from the Wyss Institute at Harvard University and the University of Illinois at Urbana-Champaign demonstrated the ability to 3D-print a battery.

• They have demonstrated 3D-IMA with a high areal energy density of 9.7 J cm − 2 at a power density of 2.7 mW cm − 2 .

• (a) gold current collector by printing (b) Li4Ti5O12 (LTO) and (c) LiFePO4 inks through 30 μm nozzles, followed by sintering and (d) packaging. Those inks solidify to create the battery's anode (red) and cathode (purple), layer by layer. A case (green) then encloses the electrodes and the electrolyte solution added to create a working microbattery.

This image shows the interlaced stack of electrodes that were printed layer by layer to create the working anode and cathode of a microbattery.

Advantage RAPID PROTOTYPING: 3D printing gives designers the ability to

quickly turn concepts into 3D models or prototypes.

Clean process.

Complex shape can be produced .

Easy to use no skilled person needed.

Reduce design complexity

Disadvantage Process is slow

Components do not have enough strength.

Cost of raw materials.

3-D printers are still expensive.

Misuse of technology

Although 3-D printers have the potential of creating

many jobs and opportunities, they might also put certain

jobs at risk .

References1. Carl Schubert, Mark C van Langeveld, Larry A Donoso.Innovations

in 3D printing: a 3D overview from optics to organs. Ophthalmol 2014;98:159–161.

2. Jea-Young Choi,a Sayantan Das,a N. David Theodore,b Inho Kim,c Christiana Honsberg, Hyung Woo Choi,and T. L. Alforda,Advances in 2D/3D Printing of Functional Nanomaterials and Their Applications.ECS Journal of Solid State Science and Technology, 4 (4) P3001-P3009 (2015).

3. Wei Zhu, JinGyu Ock, Xuanyi Ma, Wei Li and Shaochen Chen. 3D printing and nanomanufacturing. 2015 Elsevier Inc.

4. http://en.wikipedia.org/wiki/3D_computer_graphics5. Ke Sun , Teng-Sing Wei , Bok Yeop Ahn , Jung Yoon Seo , Shen J.

Dillon , and Jennifer A. Lewis,3D Printing of Interdigitated Li-Ion Microbattery Architectures , Advance material, 2013.

“The future can not be predicted,

but it can be made !”