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    Three Dimensional Printing: Innovations in Fabrication and Design for Advanced Robotics
    Three Dimensional Printing: Innovations in Fabrication and Design for Advanced Robotics
    Three Dimensional Printing: Innovations in Fabrication and Design for Advanced Robotics
    Ebook367 pages4 hoursRobotics Science

    Three Dimensional Printing: Innovations in Fabrication and Design for Advanced Robotics

    By Fouad Sabry

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    About this ebook

    In the rapidly evolving field of Robotics Science, "Three Dimensional Printing" stands as a pivotal resource that delves into the transformative technology of 3D printing. This comprehensive guide is essential for professionals, undergraduate and graduate students, enthusiasts, and hobbyists alike. By exploring various printing techniques and applications, readers will uncover how this technology is revolutionizing industries from manufacturing to healthcare. The insights gained will far outweigh the cost of the book, positioning readers at the forefront of innovation in robotics.


    Chapters Brief Overview:


    1: 3D printing: An introduction to the fundamentals of 3D printing and its significance in robotics.


    2: Selective laser sintering: Explore the technique that uses lasers to sinter powdered material into solid parts.


    3: Stereolithography: Learn about the first commercial 3D printing technology, using UV light to cure resin.


    4: Organ printing: Discover how 3D printing is used to create functional biological tissues and organs.


    5: 3D Systems: Understand the pioneering companies shaping the landscape of 3D printing technologies.


    6: Electronbeam additive manufacturing: An examination of highenergy electron beams for precise material deposition.


    7: Rapid prototyping: Insights into how quick model creation speeds up design processes and innovation.


    8: Digital modeling and fabrication: The intersection of digital design and physical production through 3D printing.


    9: Customfit: How 3D printing allows for the creation of tailormade solutions for individual needs.


    10: Selective laser melting: A deeper dive into advanced metal 3D printing techniques using lasers.


    11: Powder bed and inkjet head 3D printing: A look at a hybrid approach combining powder and liquid materials.


    12: Fused filament fabrication: Explore the most accessible 3D printing method using thermoplastic filaments.


    13: Inkjet technology: The role of inkjet printing methods in the evolution of 3D printing processes.


    14: Applications of 3D printing: A broad overview of diverse sectors benefiting from 3D printing advancements.


    15: 3D printing processes: A comparative look at various 3D printing processes and their unique applications.


    16: Material extrusionbased additive manufacturing: Investigate the mechanics of this popular 3D printing method.


    17: Cold spray additive manufacturing: Learn about a unique process utilizing highvelocity particle impact.


    18: Multimaterial 3D printing: Explore the complexities and innovations in printing with multiple materials.


    19: 3D food printing: An exciting look at how 3D printing is reshaping the culinary world.


    20: Health and safety hazards of 3D printing: Understand the potential risks associated with 3D printing technologies.


    21: 3D printed medication: Discover the future of personalized medicine through advanced 3D printing techniques.


    "Three Dimensional Printing" is more than just a book; it’s a gateway to understanding the future of robotics. Equip yourself with knowledge that enhances your skills and opens doors to new opportunities in this dynamic field.

    LanguageEnglish
    PublisherOne Billion Knowledgeable
    Release dateJan 27, 2025
    Three Dimensional Printing: Innovations in Fabrication and Design for Advanced Robotics

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      Book preview

      Three Dimensional Printing - Fouad Sabry

      Chapter 1: 3D printing

      A three-dimensional object can be constructed via additive manufacturing, often known as 3D printing, by starting with a computer-aided design (CAD) model or a digital 3D model. It can be accomplished by a variety of methods in which material is deposited, connected, or solidified under computer control. Layer by layer, the material is typically mixed together (for example, polymers, liquids, or powder grains that are fused), and the process is typically carried out in this manner.

      During the 1980s, the phrase rapid prototyping was more acceptable to use when referring to the development of 3D printing processes because it was thought that these techniques were only useful for the manufacture of prototypes that were either functional or attractive. In the purpose of this discussion, the phrase additive manufacturing can be used interchangeably with 3D printing. As of the year 2019 [update], the precision, repeatability, and material range of 3D printing have risen to the point that certain 3D printing techniques are deemed viable as a technology for industrial production. The ability to manufacture very complicated shapes or geometries that would otherwise be impossible to construct by hand is one of the primary benefits of 3D printing. This includes the ability to produce hollow components or objects with internal truss structures, which can reduce weight while also reducing the amount of material waste. Fused deposition modeling, also known as FDM, is the most prevalent type of 3D printing technology that is currently being utilized as of the year 2020 [update]. FDM makes use of a continuous filament made or thermoplastic material.

      In the 2000s, the concept of material being added together (in any of a variety of different ways) became the inspiration for the umbrella term additive manufacturing (AM), which gained prominence throughout this time period. On the other hand, the word subtractive manufacturing was coined as a retronym for the vast family of machining methods that all share the common process of material removal. In the majority of people's thoughts, the phrase 3D printing still exclusively referred to the methods that used polymers, and the term additive manufacturing was more likely to be used in situations involving metalworking and the creation of end-use parts than it was among devotees of polymer, inkjet, or stereolithography.

      By the beginning of the 2010s, the terms additive manufacturing and 3D printing had developed such meanings that they were used as alternative umbrella terms for additive technologies. One of these terms was used in common parlance by consumer-maker communities and the media, while the other was used in a more formal manner by industrial end-use part producers, machine manufacturers, and global technical standards organizations. Recently, the term three-dimensional printing has been linked to machines that are either inexpensive or limited in their capabilities. These two technologies, additive manufacturing and 3D printing, are similar in that they both involve the addition of material or the joining of materials within a three-dimensional work envelope while being controlled by an automated system. It was pointed out by Peter Zelinski, the editor-in-chief of Additive Manufacturing magazine, in 2017 that the terms are still frequently used interchangeably in casual usage. However, some experts in the manufacturing industry are attempting to differentiate between the two, stating that additive manufacturing includes 3D printing in addition to other technologies or other aspects of a manufacturing process.

      Desktop manufacturing, rapid manufacturing (as the natural production-level successor to rapid prototyping), and on-demand manufacturing (which echoes on-demand printing in the 2D meaning of printing) are some of the other phrases that have been used as synonyms or hypernyms. Desktop manufacturing represents the process of making products on a desktop computer. The fact that the application of the adjectives rapid and on-demand to the noun manufacturing was novel in the 2000s reveals the long-prevailing mental model of the previous industrial era, which was characterized by the fact that almost all production manufacturing had involved lengthy lead times for the development of laborious tooling. Today, the term subtractive has not taken the place of the term machining, but rather serves as a supplement to it in situations where a phrase that encompasses any method of removal is required. The term agile tooling refers to the process of designing tooling through the utilization of modular means. This tooling is then created through additive manufacturing or 3D printing techniques, which enables rapid prototyping and responds to tooling and fixture requirements. In order to swiftly respond to the needs of customers and the market, agile tooling employs a method that is both cost-effective and of excellent quality. This method can be utilized in a variety of production processes, including hydro-forming, stamping, injection molding, and others.

      The general concept of and procedure to be used in 3D-printing was first described by Murray Leinster in his 1945 short story Things Pass By: But this constructor is both efficient and flexible. I feed magnetronic plastics — the stuff they make houses and ships of nowadays — into this moving arm. It makes drawings in the air following drawings it scans with photo-cells. But plastic comes out of the end of the drawing arm and hardens as it comes ... following drawings only

      Raymond F. Jones also provided a description of it in his short tale titled Tools of the Trade, which was featured in the issue of Astounding Science Fiction magazine that was released in November of 1950. Within the context of that narrative, he referred to it as a molecular spray.

      A continuous inkjet metal material device that forms a detachable metal fabrication on a reusable surface for immediate use or that may be saved for printing again by remelting was patented by Johannes F. Gottwald in 1971. The device was given the number 3596285A at the United States Patent and Trademark Office. It would appear that this is the first patent that describes 3D printing with quick prototyping and regulated on-demand manufacture of patterns.

      According to the patent,

      For the sake of this discussion, the term printing is not intended to be used in a restricted sense; rather, it encompasses the generation of writing or other symbols, characters, or patterns using an ink. Not only does the term ink refer to materials that contain dye or pigment, but it also refers to any substance or composition that is able to flow and is suitable for application to a surface in order to generate symbols, letters, or patterns of intelligence by marking. A hot melt type of ink is the one that is commonly used. There is currently no information accessible regarding the variety of ink compositions that are available for commercial use and have the potential to fulfill the requirements of the invention. On the other hand, printing that is satisfactory according to the invention has been accomplished with the conductive metal alloy having been used as the ink.

      Nevertheless, in terms of the material requirements for such big and continuous displays, if consumed at rates that were previously known, but increased in proportion to the growth in size, the high cost would severely limit any general enjoyment of a method or equipment that satisfied the aforementioned aims.

      Because of this, one of the additional goals of the invention is to reduce the amount of materials that are used in a process that belongs to the specified category.

      Additionally, one of the goals of the invention is to ensure that the materials that are utilized in the process are repurposed and reclaimed.

      In accordance with another facet of the invention, a combination for writing and other similar activities consists of a carrier that displays an intelligence pattern and an arrangement that removes the pattern from the carrier.

      In the year 1974, David E. H. Jones presented the idea of three-dimensional printing in his regular column titled Ariadne, which was published in the newspaper New Scientist.

      The 1980s saw the development of the first equipment and materials for additive manufacturing manufacture.

      In April of 1980, Hideo Kodama, who worked at the Nagoya Municipal Industrial Research Institute, came up with two additive methods for creating three-dimensional plastic models using photo-hardening thermoset polymer. These methods involve controlling the UV exposure region by the use of a mask pattern or a scanning fiber transmitter.

      On November 10, 1981, he submitted a patent application for this XYZ plotter, which was subsequently published. This is the JP S56-144478.

      The results of his research were published in the form of journal papers in the months of April and November 1981.

      On the other hand, there was no response to the sequence of publications that he had released. During the laboratory evaluation, his device did not receive a good rating, and his supervisor did not show any interest in it. His research budget was only 60,000 yen, which is equivalent to $545 per year. It was decided not to pursue the acquisition of patent rights for the XYZ plotter, and the project was ultimately scrapped.

      On April 6, 1982, Raytheon Technologies Corporation was awarded a patent number 4323756 for a method of fabricating articles by sequential deposition. This patent describes the use of hundreds or thousands of layers of powdered metal and a laser energy source. This patent is an early reference to the formation of layers and the fabrication of articles on a substrate.

      Bill Masters, an American businessman, submitted a patent application for his computer-automated manufacturing process and system on July 2, 1984. The patent number for this invention was US 4665492. It was the first of three patents that belonged to Masters that created the groundwork for the 3D printing technologies that are used today. This filing is on record at the United States Patent and Trademark Office (USPTO) as the first 3D printing patent in the history of the world.

      On July 16, 1984, Alain Le Méhauté, Olivier de Witte, and Jean Claude André submitted their patent application for the process of stereolithography. The French General Electric Company, which is now known as Alcatel-Alsthom, and CILAS, which is known as The Laser Consortium, decided to forego the application that the French innovators had developed. for lack of business perspective was the reason that was cited as the cause.

      Robert Howard established R.H. in the year 1983. Using thermoplastic (hot-melt) plastic ink, research, which would eventually be renamed Howtek, Inc., was established in February 1984 with the purpose of developing a color inkjet two-dimensional printer in 1986 called Pixelmaster. A collection of individuals, including six individuals from Exxon Office Systems, Danbury Systems Division, an inkjet printer company, and a few individuals from the Howtek, Inc. group who have become well-known personalities in the 3D printing sector, were assembled into a team. Richard Helinski, a member of Howtek for whom the patent US5136515A, Method and Means for creating three-dimensional products by particle deposition, was granted on August 4, 1992, established a firm in New Hampshire called C.A.D-Cast, Inc., which later changed its name to Visual Impact Corporation (VIC) on August 22, 1991. This business has made accessible a prototype of the VIC 3D printer, which comes with a video presentation that demonstrates a 3D model that was manufactured using an inkjet printer with a single nozzle. Herbert Menhennett, another employee, established HM Research in New Hampshire in 1991. He was the one who offered the inkjet technology and thermoplastic materials developed by Howtek, Inc. to Royden Sanders of SDI and Bill Masters of Ballistic Particle Manufacturing (BPM), where he had worked for a number of years. When it comes to 3D printing, both BPM 3D printers and SPI 3D printers use inkjets and materials that are of the Howtek, Inc. company. Before Sanders prototype, Inc. (SPI) began production of the Modelmaker 6 Pro in 1993, Royden Sanders obtained a license to use the Helinksi patent. After being hired by Howtek, Inc. to assist in the development of the inkjet, James K. McMahon went on to work at Sanders Prototype and is now the proprietor of Layer Grown Model Technology, a 3D service provider that specializes in providing support for Howtek single nozzle inkjet and SDI printers. While working at Exxon, James K. McMahon collaborated with Steven Zoltan, the creator of the drop-on-demand inkjet in 1972. McMahon was awarded a patent in 1978 for his work, which contributed to the improvement of Howtek, Inc.'s hot-melt inkjets and broadened the understanding of the single-nozzle design inkjets known as Alpha jets. This hot-melt thermoplastic technology developed by Howtek is becoming increasingly popular in the field of metal investment casting, particularly in the field of 3D printing jewelry. The first customer for Sanders (SDI) Modelmaker 6Pro was Hitchner Corporations, Metal Casting Technology, Inc., located in Milford, New Hampshire, approximately one mile away from the SDI factory. They engaged in the casting of golf clubs and auto engine parts during the late 1993-1995 period.

      A patent application for a stereolithography fabrication system was submitted on August 8, 1984. The patent, which was initially assigned to UVP, Inc. and was later assigned to Chuck Hull of 3D Systems Corporation, was Hull's own invention. The system allows for the addition of individual laminae or layers through the curing of photopolymers through impinging radiation, particle bombardment, chemical reaction, or simply ultraviolet light lasers. In his definition of the process, Hull referred to it as a method for making three-dimensional objects by creating a cross-sectional pattern of the object to be made. Additionally, Hull was responsible for the development of the STL (Stereolithography) file format as well as the digital slicing and infill procedures that are utilized in a variety of processes today. In 1986, Charles Chuck Hull was awarded a patent for this technology. In the same year, his company, 3D Systems Corporation, was established, and it was later in 1987 or 1988 that the company introduced the SLA-1, which was the first commercially available 3D printer.

      Fused deposition modeling, a specialized application of plastic extrusion that was created in 1988 by S., is the technique that continues to be utilized by the majority of 3D printers to this day, particularly those that are geared toward hobbyists and consumers. The first FDM machine was marketed by Scott Crump's firm, Stratasys, in the year 1992. That machine was commercialized by Stratasys.

      In the 1980s, the cost of owning a 3D printer was upwards of $300,000, which is equivalent to $650,000 in today's money.

      In the 1980s and 1990s, additive manufacturing (AM) technologies for metal sintering or melting (such as selective laser sintering, direct metal laser sintering, and selective laser melting) typically went by their own individual names. Although a great deal of automation was applied to those technologies (such as by robot welding and CNC), the concept of a tool or head moving through a three-dimensional work envelope and transforming a mass of raw material into a desired shape with a toolpath was only associated in the field of metalworking with processes that removed metal (rather than adding it), such as CNC milling, CNC EDM, and many others. At the time, all metalworking was done by processes that are now known as non-additive processes (casting, fabrication, stamping, and machining). Nevertheless, the automated processes that added metal, which would eventually be referred to as additive manufacturing, were beginning to call into question the validity of that notion. Microcasting and sprayed materials were two of the innovative methods for material deposition that were developed by Stanford University and Carnegie Mellon University by the middle of the 1990s. Additionally, the prevalence of sacrificial and support materials had increased, which made it possible to create novel object geometries.

      When it was first introduced, the term three-dimensional printing referred to a powder bed method that utilized both standard and custom inkjet print heads. This technology was initially developed by Emanuel Sachs at the Massachusetts Institute of Technology in 1993 and then commercialized by Soligen Technologies, Extrude Hone Corporation, and Z Corporation. [Source:]

      An inkjet 3D printer firm that was initially known as Sanders Prototype, Inc. and then changed its name to Solidscape was established in 1993. This company was responsible for the introduction of a high-precision polymer jet production system that had soluble support structures. This approach is referred to as a dot-on-dot technology.

      The selective laser melting technology was discovered and developed by the Fraunhofer Society in the year 1995.

      In the early 2000s, 3D printers were still mostly utilized in the industrial and research industries. This was due to the fact that the technology was still in its infancy and was too expensive for the majority of customers to be able to acquire. The decade of the 2000s marked the beginning of the beginning of larger-scale applications of the technology in industry, most frequently in the fields of architecture and medicine. However, the technology was typically utilized for low-accuracy modeling and testing, rather than for the production of conventional manufactured goods or heavy prototyping.

      In 2005, people started designing and distributing designs for 3D printers that could print approximately 70 percent of their own parts. The initial plans for these printers were designed by Adrian Bowyer at the University of Bath in 2004, and the project was given the term RepRap, which stands for Replicating Rapid-prototyper.

      In a similar manner, Evan Malone and Hod Lipson initiated the Fab@Home project in the year 2006. This was yet another project that aimed to construct a low-cost and open-source fabrication system that users could develop on their own and give feedback on. This project was designed to be very collaborative.

      As a result of the fact that the majority of the software for 3D printing that was accessible to the general public at the time was open source, it was rapidly disseminated and built upon by a large number of individual users. Patents for the Fused Deposition Modeling (FDM) printing technology were no longer valid through the year 2009. This resulted in the establishment of a new wave of startup firms, many of which were founded by important contributors to these open source initiatives. The objective of many of these companies was to begin the process of building commercial FDM 3D printers that were more accessible to the general public.

      A mass of raw material would be transformed into a desired shape layer by layer as the various additive processes progressed. It became evident that metal removal would soon no longer be the sole metalworking process done by a tool or head moving through a three-dimensional work envelope. This was the case since metal removal was no longer the only process. In the 2010s, metal end-use parts such as engine brackets and huge nuts were grown (either before or instead of machining) in job production for the first time. Previously, these parts were machined from bar stock or plate. However, this was the first decade in which this practice was implemented. It is still the case that casting, fabrication, stamping, and machining are more common in the metalworking industry than additive manufacturing; however, additive manufacturing is now beginning to make significant inroads, and with the benefits of design for additive manufacturing, it is clear to engineers that much more is to come in the future.

      The aviation industry is one sector in which AM is making great headway in terms of its market share. The need for jet engines that are both fuel efficient and easy to construct has never been bigger than it is in 2016, when there were approximately 3.8 billion people who traveled by air. For large original equipment manufacturers (OEMs) such as Pratt and Whitney (PW) and General Electric (GE), this means looking to additive manufacturing (AM) as a means of lowering costs, reducing the number of nonconforming parts, lowering the weight of the engines in order to improve fuel efficiency, and discovering new, highly complex shapes that would not be possible using the traditional manufacturing methods. In 2016, Airbus delivered the first of GE's LEAP engines, which is an example of how additive manufacturing may be integrated into the aerospace industry. This engine includes integrated gasoline nozzles that were created using 3D printing technology, which reduces the number of parts from twenty to one, resulting in a weight reduction of twenty-five percent and a reduction in assembly times. Additionally, because it is a low-stress, non-rotating part, a fuel nozzle is the ideal inroad for additive printing in a jet engine. This is because it enables the optimization of the design of the intricate internals of the engine. By the same token, in 2015, PW shipped their very first AM components to Bombardier in the form of the PurePower PW1500G. The compressor stators and synch ring brackets were chosen by PW to bring this innovative manufacturing process to the market for the very first time. PW chose these components because they are low-stress and cannot rotate. The return on investment can already be seen by the decrease in parts, the speedy production capabilities, and the optimal design in terms of performance and cost. Despite the fact that additive manufacturing is still playing a very minor role in the total number of parts that are used in the manufacturing process of jet engines, the return on investment is

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