What is 3D printing?

It is a process, which builds a three-dimensional object from a computer-

aided design (CAD) model, usually by successively adding material layer by
layer, which is why it is also called additive manufacturing, unlike
conventional machining, casting, and forging processes. Where material is
removed from a stock item (subtractive manufacturing) or poured into a
mold and shaped by means of dies, presses and hammers.

Terminology
The term Additive manufacturing (AM) gained popularity in the 2000s,
inspired by the theme of material added together. In contrast, the term
subtractive manufacturing appeared as a retronym for the large family of
machining processes with material removal as their common theme. The
term 3D printing still referred only to the polymer technologies in most
minds, and the term AM was more likely to be used in metalworking and
end use part production contexts than among polymer, ink-jet.
General principles

Modeling: 3D printable models may be created with a computer-aided design

(CAD) package, via a 3D scanner, or by a plain digital camera and photogrammetry
software. 3D printed models created with CAD result in reduced errors and can be
corrected before printing, allowing verification in the design of the object before
it is printed. The manual modeling process of preparing geometric data for 3D
computer graphics is similar to plastic arts such as sculpting. 3D scanning is a
process of collecting digital data on the shape and appearance of a real object,
creating a digital model based on it.

CAD models can be saved in the stereo lithography file format (STL), a de facto
CAD file format for additive manufacturing that stores databased on
triangulations of the surface of CAD models. STL is not tailored for additive
manufacturing because it generates large file sizes of topology optimized parts
and lattice structures due to the large number of surfaces involved. A newer CAD
file format, the Additive Manufacturing File format (AMF) was introduced in 2011
to solve this problem. It stores information using curved triangulations.

Printing: Before printing a 3D model from an STL file, it must first be examined
for errors. Most CAD applications produce errors in output STL files, of the
following types:

Holes; faces normals; self-intersections; noise shells; manifold errors.

A step in the STL generation known as "repair" fixes such problems in the original
model. Generally, STLs that have been produced from a model obtained through
3D scanning often have more of these errors. This is due to how 3D scanning
works-as it is often by point-to-point acquisition, 3D reconstruction will include
errors in most cases.

Once completed, the STL file needs to be processed by a piece of software called
a "slicer," which converts the model into a series of thin layers and produces a G-
code file containing instructions tailored to a specific type of 3D printer (FDM
printers). This G-code file can then be printed with 3D printing client software
(which loads the G-code, and uses it to instruct the 3D printer during the 3D
printing process).

Printer resolution describes layer thickness and X–Y resolution in dots per inch
(dpi) or micrometers (µm). Typical layer thickness is around 100 μm (250 DPI),
although some machines can print layers as thin as 16 μm (1,600 DPI). X–Y
resolution is comparable to that of laser printers. The particles (3D dots) are
around 50 to 100 μm (510 to 250 DPI) in diameter.[citation needed] For that
printer resolution, specifying a mesh resolution of 0.01–0.03 mm and a chord
length ≤ 0.016 mm generate an optimal STL output file for a given model input
file. Specifying higher resolution results in larger files without increase in print
quality.

Multi-material printing: Multi-material printing allows objects to be

composed of complex and heterogeneous arrangements of materials. It requires a
material being directly specified for each voxel inside the object volume. The process is
fraught with difficulties, due to the isolated and monolithic algorithms. There are many
different ways to solve these problems, such as building a Spec2Fab translator.

Multi-material 3D printing is a fundamental element for development of future

technology. It has been already applied to variable industries. Other than common
applications in small manufacturing industries, to produce toys, shoes, furniture, phone
cases, instruments or even artworks. With the BAAM (Big Area Additive Manufacturing)
machine, large products such as 3D printed houses or cars are quite feasible. It has also
been widely used in high-tech industries. Researchers are devoting to producing high-
temperature tools with BAAM for aerospace applications.

In medical industry, a concept of 3D printed pills and vaccines has been recently brought
up. With this new concept, multiple medications are capable of being united together,
which accordingly will decrease many risks. With more and more applications of multi-
material 3D printing, the costs of daily life and high technology development will
become irreversibly lower.
 Automotive 3D Printing Applications
For the automotive industry, recent advances in Additive Manufacturing (AM) (or
3D Printing) have opened doors for newer, more robust designs; lighter, stronger,
and safer products; reduced lead times; and reduced costs. In 2015, the annual
Wohler’s report stated that the automotive industry accounted for 16.1% of all AM
expenditure. While automotive original equipment manufacturers (OEMs) and
suppliers primarily use AM for rapid prototyping, the technical trajectory of AM
makes a strong case for its use in product innovation and direct manufacturing in
the future.
 AM in the automotive industry

Designs in the automotive industry often begin as scale models highlighting the
form of a vehicle. These are often also regularly used for aerodynamic testing. SLA
Communication and material jetting are used to produce high detail, smooth, scale models of
automotive designs. Accurate models allow design intention to be clearly
communicated and highlight the overall form of a concept.

Prototyping using AM is now commonplace in the automotive industry. From a full

size wing mirror printed quickly with low cost FDM to a high detail, full color
Validation dashboard, there is an AM technology suited to every prototyping need. Some AM
engineering materials also allow for full testing and validation of prototype
performance.

One of the areas AM has been most disruptive is the production of low cost rapid
tooling for injection molding, thermoforming, jig, and fixtures. Within the automotive
Pre-production industry, this allows for tooling to be quickly manufactured at a low cost and then
used to produce low to medium runs of parts. This validation mitigates the risk when
investing in high cost tooling at the production stage.

Since production volumes in the automotive industry are generally very high
(greater than 100,000 parts per year) AM has predominantly been used as a
prototyping solution rather than for end part manufacturing. Improvements in the
Production size of industrial printers, the speed they are able to print at and the materials that
are available mean that AM is now a viable option for many medium-sized
production runs, particularly for higher-end automobile manufacturers that restrict
production numbers to far fewer than the average. .

AM has had a significant impact on the competitive automotive industry when the
cost of highly complex one-off components is justified by a substantial improvement
in vehicle performance. Parts can be tailored to a specific vehicle (custom,
Customization
lightweight suspension arms) or driver (helmet or seat). AM has also allowed part
consolidation and optimize topography of many custom automotive components.
This is further highlighted in the case studies found at the end of this article.
 AM materials suited for automotive applications
The table below presents a range of materials used in the automotive industry along
with the associated application.

Application Process Material Features Example part

Heat resistant functional

Under the hood SLS Nylon Battery cover
parts

Customized cosmetic Console

Interior accessories SLA Resin
components prototype

Flexible ducting and Air conditioning

Air ducts SLS Nylon
bellows ducting

Large parts with a surface

Industrial finish comparable to
Full scale panels Resin Front bumper
SLA injection molding that allow
for sanding and painting

Alternator
Cast metal brackets SLA & Metal parts made from 3d
Wax mounting
& handles cast printed patterns
bracket

Complex metal Consolidated, lightweight, Suspension

DMLS Metal
components functional metal parts wishbone

Material End use custom screen Dashboard

Bezels Photopolymer
jetting bezels interface

Fully transparent, high Headlight

Lights SLA Resin
detail models prototypes