# **WHAT IS ADDITIVE MANUFACTURING/3D PRINTING?**

Additive manufacturing is also popularly known as 3D printing. As the name suggests manufacturing of products also proceeds further in a similar manner i.e., by the addition of material in layers format, this process is followed till the desired object is complete, hence the name is additive manufacturing. Here the final object is made based on a digital model, which is basically a CAD model or scanned model from a 3D object scanner. It's also known as 3D printing because it provides an extra
axis i.e., the z-axis unlike in normal printers which provide only 2 axes, helps to create a 3D object Therefore it's known as 3D printing.

# **HOW DOES 3D PRINTING CREATE OBJECTS COMPARED TO TRADITIONAL METHODS?**

Traditional manufacturing
methods generally follow subtractive manufacturing techniques that involve even
formative processes, where the material is removed or shaped from a larger
piece to create the desired object. This includes techniques like machining,
milling, modelling and many more. 3D printing is quite different from
traditional manufacturing methods in it begins by Creating 3D objects from CAD
files and then is sliced using various slicing software which slices the 3D
model into fine layers which is then loaded to the printer where repeatedly
layering down of thin layers of materials occurs Until the final product is
completed. This uses software like Autodesk Fusion 360, Ultimaker Cura, Prusa
Slicer, Tinker Cad, and Blender.

# **WHAT IS THE DIGITAL BLUEPRINT AND WHY IT’S USED IN 3D PRINTING?**

A digital blueprint for 3D printing is a
computer-aided CAD file. It contains the required instructions for a 3D printer
to create an object. These blueprints can be created using various CAD software
and saved in different formats like STL, OBJ, or AMF.

# **WHAT TYPES OF MATERIALS ARE USED IN 3D PRINTING?**


These materials can are
generally used apart from these there are other materials available which can
also be used:

**PLASTICS** -PLA (Polylactic Acid), ABS
(Acrylonitrile Butadiene Styrene), PETG (Polyethylene Terephthalate Glycol),
TPU (Thermoplastic Polyurethane), Nylon, PVA (Polyvinyl Alcohol),
PC(Polycarbonate), HIPS (High-impact polystyrene) etc.

**METALS**    -Aluminium, Titanium, Copper, Steel,
Cobalt-chrome, Inconel.

**CERAMICS** Porcelain,Alumina,Zirconia**COMPOSITES** Carbon Fiber, Glass Fiber, Kevlar

**ADVANCED MATERIALS** Graphene, Carbon Nanotubes, Silicon
Carbide

**POLYMERS** -PEEK (Polyether Ether Ketone),
PMMA(Polymethylmethacrylate)

ULTEM(Polyetherimide), ASA(Acrylonitrile Styrene Acrylate) and many
more.

# **MAKE YOUR FIRST 3D PRINT BY FOLLOWING THESE SIMPLE STEPS**

Creating a 3D print in four steps:

**1. Design:** Create or download a 3D model in a compatible format (e.g.,
STL,OBJ,AMF,3MF).

**2. Prepare:** Set up your 3D printer, load filament, and ensure proper
settings.

**3. Slice and Print:** Use slicing software to prepare your model, transfer
it to the printer, and start printing.

**4. Post-Processing:** Remove the printed object, clean up any supports, and
finish as needed (e.g., sanding, painting).


#

# **3D PRINTING JUNCTURES**

The 3D printing process typically involves several stages,
although the specific steps may vary depending on the technology and materials
used. Here are the major steps involved in the 3D printing process:

**1. Design:**

The design phase
begins with the development of a 3D model for the object, employing various
resources such as computer-aided design (CAD) software, 3D scanners,
photogrammetry, 3D printing pens, generative design, parametric design, and
scripting. This digital design file, commonly known as the blueprint, acts as
the initial stage in the 3D printing process.

**2. Pre-processing:**

Before initiating the 3D printing process, it's essential to
prepare the 3D model in accordance with your envisioned design, as well as the
specific 3D printing technology and chosen material. This preparation involves
various tasks, including segmenting the model into distinct layers,
establishing support structures, and configuring a range of settings, including
print parameters.

**3. Printing:**

The 3D printer executes instructions derived
from the pre-processed model, crafted earlier, to construct the object
incrementally, layer by layer. The specific printing technique employed,
whether it involves extruding filament, curing resin, or sintering powder, can
vary depending on the chosen technology.

**4. Post-processing:**

After the printing phase, the object typically undergoes
post-processing aimed at enhancing its overall quality, visual appeal, or
functionality. This stage commonly involves tasks like the removal of support
structures, sanding, painting, or the application of additional finishing
methods.

**5. Inspection and Quality Control:**

A thorough
examination of the printed object is conducted to verify its alignment with the
specified requirements and quality benchmarks outlined by the client. This
inspection encompasses various aspects, including visual scrutiny, dimensional
measurements, functional testing, and additional checks as necessary.

**6. Assembly (if necessary):**

When dealing with
objects composed of multiple components or intricate geometries, assembly is
conducted in a dedicated assembly section following the printing phase. Here,
parts are interconnected employing methods such as adhesives, screws,
soldering, or other suitable fastening techniques.

**7. Finishing and Packaging:**

This marks the concluding phase,
encompassing an array of supplementary refinements such as polishing, coating,
or labelling, all aimed at elevating the quality and surface finish of the
objects. Once these finishing touches are applied, the finalized objects are
meticulously packaged and made ready for distribution, a task overseen by the
company's distribution team.


# Basis for classification of 3D printing

printing technologies can be broadly classified based on various criteria such
that each one of them highlights unique aspects of the processes. Below are the
following common bases for the classification of 3D printing:

---

**Process/Technology** **:  In this criterion, classification is based on the underlying technology or process.

**Material type:** a classification of 3D printing processes based on the type of
materials they use.

**Material State:** a classification of the 3D printing
process based on material state.

**Layering Approach:** a classification of 3D printing based on the addition
of layers.

**Resolution/Detail Level:** a classification of 3D printing based
on resolution or detail level

**Application Area:** a classification of 3D printing based on primary
application Areas.

**Material Processing:** It's classified based on the way the
material is processed.

**Industrial/Consumer:** It's classified based on their typical
usage in industrial, desktop or consumer usage.

**Biocompatibility:** classification of 3d printers based on their
compatibility for producing biocompatible 3d printers.

**Post Processing Requirements:** classification based on their post
processing requirements.

**Production Volume:** a classification based on production
volume suited to different scales of production

**Print speed:** Printers can be classified based on their print speeds into
various categories, ranging from slower desktop printers to faster industrial
and production-grade machines. Keep in mind that print speed is influenced by
factors like layer height, complexity of the object, and chosen print settings.
Here's a classification based on print speeds.

# **CLASSIFICATION BASED ON PROCESS:**

**FDM-** FUSED DEPOSITION MODELLING

**SLA-** STEREOLITHOGRAPHY

**DLP-** DIGITAL LIGHT PROCESSING

**SLS-** SELECTIVE LASER SINTERING

**SLM-** SELECTIVE LASER MELTING

**EBM-** ELECTRON BEAM MELTING

**BINDER JETTING**

**MATERIAL JETTING**

**LOM-** LAMINATED OBJECT MANUFACTURING

**DED-** DIRECTED ENERGY DEPOSITION

**CLIP-** CONTINUOS LIQUID INTERFACE PRODUCTION

**INKJET 3D PRINTING**

**POWER BED**

**HYBRID PROCESSES**

# **CLASSIFICATION BASED ON MATERIAL TYPE**

**PLASTICS AND POLYMERS**

**METALS**

**COMPOSITES**

**CERAMICS AND GLASSES**

**BIOLOGICAL AND FOOD MATERIALS**

**OTHER MATERIALS**

# **CLASSIFICATION BASED ON MATERIAL STATE**

**LIQUID RESION**

**POWDER**

**THERMOPLASTIC FILAMENT**

**LIQUID/GEL INK**

**SOLID SHEETS/LAYERS**

**WIRE/RODS**

**OTHER STATES**

# **CLASSIFICATION BASED ON LAYERING APPROACH**

**ADDITIVE APPROACH**

**SUBTRACTIVE APPROACH**

# **CLASSIFICATION BASED ON RESOLUTION**

**HIGH RESOLUTION**

**MODERATE RESOLUTION**

**LOW RESOLUTION**

# **CLASSIFICATION BASED ON APPLICATION AREA**

**PROTOTYPING & MANUFACTURING**

**AEROSPACE & AUTOMOTIVE**

**HEALTH CARE**

**ART & DESIGN**

**EDUCATION & RESEARCH**

**FOOD AND CULINARY APPLICATION**

# **CLASSIFICATION BASED ON MATERIAL PROCESSING**

**MELTING & SOLIDIFYING**

**PHOTOPOLYMERIZATION**

**EXTRUSION**

**JETTING & CURING**

**POWDER BINDING**

**SHEET LAYERING**

**SPECIAL TECHNIQUES**

# **CLASSIFICATION BASED ON INDUSTRIAL/CONSUMER USAGE**

**INDUSTRIAL**

**CONSUMER**

**DESKTOP**

# **CLASSIFICATION BASED ON POST-PROCESSING REQUIREMENTS**

**MINIMAL POST-PROCESSING**

**MODERATE POST-PROCESSING**

**SIGNIFICANT POST-PROCESSING**

**CLASSIFICATION BASED ON BIOCOMPATIBILITY**

**BIOCOMPATIBLE PROCESSES**

**POTENTIALLY BIOCOMPATIBLE PROCESSES**

**LESS BIOCOMPATIBLE PROCESS**

# **CLASSIFICATION BASED ON PRINTSPEED**

**LOW TO MODERATE SPEED**

**MODERATE**

**MODERATE TO HIGH**

**HIGH SPEED**

**VERY HIGH SPEED**

**VARIABLE SPEEDS**


# MANUFACTURING SHOWDOWN  -  A **Battle** between **3D Printing** & **Traditional Manufacturing**

3D printing offers a wide range
of unparalleled characteristics which makes it exclusive let's start with
production speed if we carefully observe the production process and its sprint
in both processes, we find that 3D printing is more prompt compared to
traditional processes. These are generally slow processes as they are
subtractive, formative, and even require frequent tool changes and lead time is
also high therefore in this case 3D Printing takes an upper hand.

Wait for a while it's not over yet! we will now consider that flexibility and
pliancy gain an upper hand in 3D printing, this is because of various
manufacturing constraints to the traditional processes, if we take a look at 3D
printing it is not constrained as much as the former one due to which this
stage is also lead by 3D printing.

Currently,mass production, strength, durability, and regulatory compliance are the
sectors dominated by traditional methods but it won't be so in the near future
because the 3D printing sector is developing at a phenomenal pace and even
embedding Machine Learning which gives us the hope to raise up as early as
possible. Traditional methods outmanoeuvre 3D Printing at this stage.

Post-processing and waste generation are comparatively less in 3D printing and even the waste
can be reused to generate gallery or other showcase items in the case of 3D
printing by converting waste into pellets through a pellet extruder but in
traditional methods it’s not the case they require extensive finishing, and
much wastage is produced.

Finally, it is time to conclude
the Battle’s result as in the case of Batch production 3D printing surpasses
traditional methods while if it’s the case of cost-effective mass production,
compliance, and speed in some cases such as injection moulding, die casting
etc. traditional methods establish supremacy.



## Introduction

Binder Jetting is a powerful and versatile additive manufacturing technology that offers a cost-effective and rapid production method of 3D printing. Due to its wide material compatibility, including metals, ceramics, and sand, powder self-support and high-volume production, Binder Jetting is considered to be one of the most promising 3D printing technologies. These advanced printers are capable of producing highly detailed and complex geometries with remarkable efficiency.

A Binder Jetting machine 3D prints the model by selectively depositing a liquid binding agent onto a layer of powder material. The binding agent acts as an adhesive, selectively deposited onto a bed of powder material to bond the particles together. The process is similar in working to a classical inkjet 2D printer, however the Binder Jet builds a 3-dimensional object by “slicing” the model and printing layer by layer.

### How does a Binder Jet print a 3D model?

First we need to design and slice our 3D model before printing. In general, you can follow these steps:

- Create your 3D model using common 3D CAD (Computer Aided Design) design software such as Fusion360, Solidworks, Blender, etc.
- Export the 3D model in a format supported by the slicing software used with your 3D printer. Common formats include STL, OBJ, or 3MF
- Use the slicing software to ”slice” the 3D model into thin horizontal layers. This process generates the toolpaths and instructions (G-code) necessary for the 3D printer.
- Load the sliced file into the 3D printer’s control interface and start the printing process.

For more beginner friendly information, you can visit [3D Printing Unveiled: A Beginner's Guide](https://mekuva.com/blog/1). To read further on [slicing software](https://all3dp.com/2/what-is-a-3d-slicer-simply-explained/).

<ArticleImage src="/posts/binder-jetting.webp" />
Schematic of a typical binder jetting 3D printing process. Image via Quora

The Binder Jet machine prints your 3D model by the following steps:
- First, a recoating blade or head spreads a thin layer of powder over the machine’s build platform.
- Next, the printhead (a carriage with inkjet nozzles, similar to those used in desktop 2D printers) precisely jets the binding agent into the powder according to the part’s geometry.
- When the binder layer is complete, the build platform lowers, and the re-coater spreads a fresh layer of powder across the platform and top of the part being printed.
- The printhead binds another layer and this process repeats until the build is complete. Based on the material, some amount of postprocessing might be required.

### Why do we need Binder Jetting?

 - **Binder Jetting** is relatively productive and cost-effective compared to other 3D printing processes. It can run unattended, offering an automated way to produce a range of components with minimal human interference.
- **Rapid mass production:** 3D core parts are supported by unused powder and can therefore be stacked in three dimensions, allowing for efficient nesting to produce more parts per run (high volumetric output).
- **Speed and precision:** It's up to 10 times more economical than selective laser sintering (SLS) or selective laser melting (SLM) and offers relatively large build sizes of up to 800 x 500 x 400 mm. 
- **Material diversity:** Binder Jetting offers remarkable material diversity, accommodating a wide range of powders suitable for various applications. This includes metals, ceramics, polymers, and even composite materials.
- **Powder reuse:** Without the influence of heat in the build chamber, unused powder doesn't degrade and can be recycled back into the process, so effectively powder untouched by the binder is essentially the same coming out of the build envelope as it was going into the printer.

### Sources :

- [ExOne](https://www.exone.com/en-US/Resources/case-studies/what-is-binder-jetting)
- [Additive Manufacturing Media](https://www.additivemanufacturing.media/articles/am-101-binder-jetting)
- [All3DP](https://all3dp.com/1/betting-on-binder-jetting-for-production-additive-manufacturing/)
- [TWI](https://www.twi-global.com/technical-knowledge/faqs/what-is-binder-jetting#Advantages)
- [3DNatives](https://www.3dnatives.com/en/powder-binding100420174/)

# Post-processing

Post-processing techniques represent the final stage in the 3D printing workflow, occurring
after the initial printing process is complete. These techniques aim to enhance
the visual appeal, functionality, or material properties of the printed object.
Below are several commonly employed post-processing methods in the realm of 3D
printing:

**Support
Structure Removal:**
In many 3D printing methods, support structures are necessary to facilitate the
printing of overhangs and intricate geometries. The first step in
post-processing typically involves the systematic removal of these support
structures.

**Sanding
and Smoothing:**
Abrasive tools, including sandpaper, are used to refine surfaces, eliminate
layer lines, and improve the overall texture and finish of the object.

**Priming
and Painting:** To
enhance the aesthetics of the printed item, primers and paints can be applied,
introducing color and providing protective coatings.

**Assembly:** For objects comprised of multiple
components, assembly becomes a requisite post-printing step. Techniques such as
gluing, snapping, or fastening are commonly employed to join these parts
together.

**Filling
and Bonding:** Gaps,
seams, or imperfections can be filled using fillers, epoxy, or adhesives,
enabling the bonding of different parts.

**Polishing:** The application of buffing and
polishing compounds can achieve a glossy or reflective surface on printed
components.

**Heat
Treatment:** In
certain cases, the application of heat to materials like thermoplastics can
enhance strength, alleviate stress, or improve mechanical properties.

**Painting
and Coating:** Beyond
priming, specialized coatings like varnishes, sealants, or protective layers
can serve both aesthetic and functional purposes.

**Dyeing
and Colouring** ’s
materials allow for custom colouring or dyeing to achieve unique colours and
patterns.

**Electroplating:** In the context of metal 3D prints,
electroplating is employed to deposit a metal layer onto the surface,
augmenting appearance, and material properties.

**Laser
Etching and Engraving:** Laser technology provides precision for etching or engraving intricate
details onto the object's surface.

**Chemical
Finishing:** Chemical
treatments, such as vapor smoothing or chemical baths, can be employed to
dissolve or refine the surfaces of specific materials.

**Sandblasting:** Utilizing high-pressure sandblasting
is a method to eliminate layer lines and impart a matte finish to the
object."



## Introduction

Laser cutting is a precision manufacturing process that has revolutionized the way various materials are cut and shaped across a multitude of industries. Using a high-powered laser beam, laser cutting technology enables the precise and efficient cutting of materials such as metal, plastic, wood, fabric, and more. This process is guided by computer numerical control (CNC) systems, allowing for intricate and complex designs to be executed with remarkable accuracy.

The fundamental principle behind laser cutting involves focusing a **concentrated beam of light**, typically a laser, onto the surface of the material to be cut. The intense heat generated by the laser melts, burns, or vaporizes the material, creating a clean and precise cut along the desired path. The speed, intensity, and focus of the laser beam are carefully controlled to achieve the desired cut, making laser cutting a highly versatile and adaptable manufacturing technique.

<ArticleImage src="/posts/laser/laser-2.webp" />

Laser cutting offers numerous advantages over traditional cutting methods, including **high precision, minimal material waste, quick production speeds, and the ability to cut intricate patterns or designs**. This process is widely utilized in industries such as automotive, aerospace, electronics, fashion, signage, and many others, contributing significantly to the advancement and innovation in modern manufacturing. In this introduction, we will delve deeper into the various aspects of laser cutting manufacturing, exploring its applications, benefits, machinery involved, and the overall impact it has on the manufacturing landscape.
Delving into advanced laser cutting manufacturing techniques and their wide-ranging applications reveals the transformative impact of this technology.

Laser cutting involves utilizing a focused, high-intensity laser beam to cut or engrave a variety of materials, ensuring exceptional precision and speed. Controlled by computer numerical control (CNC), this process guarantees accuracy and repeatability, making it highly suitable for intricate designs and detailed cuts.

### Key Advantages:

Micron-Level Precision: Laser cutting achieves extraordinary precision, crucial for intricate designs.
Swift Processing: The laser beam enables efficient material processing, enhancing overall manufacturing speed.
Material Versatility: It can cut a broad range of materials, from metals to plastics.

## Types of Laser Cutting

**CO2 Laser Cutting** : CO2 lasers, using a gas mixture, excel in cutting non-metallic materials like wood and acrylic.

<ArticleImage src="/posts/laser/laser-3.webp" />

**Fiber Laser Cutting** : Fiber lasers, powered by solid-state laser sources, efficiently cut various metals, including steel and aluminum.

<ArticleImage src="/posts/laser/laser-4.webp" />

**Nd : YAG Laser Cutting** : Solid-state Nd:YAG lasers are ideal for cutting thicker materials and highly reflective metals.

<ArticleImage src="/posts/laser/laser-5.webp" />

**Key Advantages** : Material Adaptability: Different laser types cater to specific materials, optimizing performance.
Efficiency: Fiber lasers, in particular, offer high efficiency and cost-effectiveness.

## Advanced Techniques and Innovations

**Laser Microjet Cutting** : Laser microjet cutting combines laser and water, enabling precise cutting of delicate materials with reduced thermal stress.

<ArticleImage src="/posts/laser/laser-6.webp" />

**Laser Fusion Cutting** : Laser fusion cutting involves melting the material with the laser and using high-pressure gas to remove molten material.

<ArticleImage src="/posts/laser/laser-7.webp" />

**Key Advantages:**

Enhanced Edge Quality: Advanced techniques provide superior edge quality and reduced thermal distortion.
Optimized Speed and Accuracy: These techniques result in faster cutting speeds and increased accuracy.
Advanced Laser Cutting Techniques


**Credits**

[Alejandro Martinez-Conde](https://www.researchgate.net/figure/Diagram-of-CO2-laser-cutting-assisted-by-a-gas-with-all-principal-parts-involved-in-the_fig1_316263580)

[Michael Reilly](https://www.quora.com/If-laser-processes-are-from-a-few-percent-to-maybe-20-percent-why-not-skip-the-laser-part-and-just-collimate-focus-the-source-light-directly-for-burning-and-cutting)

[Jimmy](https://www.stylecnc.com/industry-news/Fiber-laser-cutting-machine-precision-analysis.html)

[Advances in Laser Materials Processing and Applications](https://www.mdpi.com/1996-1944/15/24/8998)

[TechBriefs](https://www.techbriefs.com/component/content/article/tb/supplements/ptb/features/applications/12118)

[A.Riviero](https://www.sciencedirect.com/science/article/pii/S0141635917301599)

## Conclusion

The continuous evolution of laser cutting technology revolutionizes the manufacturing industry, enhancing precision, efficiency, and adaptability. Manufacturers in Hyderabad, India, and worldwide can achieve exceptional results across various applications by staying updated on the latest advancements in laser cutting.

For further inquiries or expert assistance with laser cutting techniques, reach out to our team at [contactus@mekuva.com](mailto:contactus@mekuva.com?subject=Product%20%2F%20Service%20Inquiry)


## Introduction

3D Scanners are transformative devices that bring real-world objects into the digital realm. While they might seem similar to advanced paper scanners, the intricacies involved in converting tangible objects into computer designs are far more complex. These designs, once digitized, open up a world of possibilities. But, as with all technologies, there's a steep learning curve and numerous pitfalls.

The surge in 3D scanning's popularity is evident. Modern devices, with their state-of-the-art features, have revolutionized industries like reverse engineering and medicine. They're invaluable for enhancing or recreating designs, especially when original CAD or STL files are absent. But, mastering this technology isn't easy. That's where our expertise comes in. Dive into our other blog articles for more on 3D printing and product design.

<ArticleImage src="/posts/3d-scan-2.webp" />

### The Complex World of 3D Scanners


3D scanners come in various types and form factors:

- **Laser & IR Scanners:** While these are the primary categories, hybrid devices combine both.
- **Form Factors:** From enclosed units to handheld devices, the choices are vast.

Some might argue that recent smartphones, like the iPhone 14 Pro series, with LIDAR capabilities, can handle 3D scans. However, the results often fall short of professional standards. While consumer-grade scanners might seem tempting, achieving optimal results requires expertise.

**Consumer-Grade vs. Professional Scanners:**

**Einstar 3D Scanner by Shining3D:** A handheld device, affordable but requires a skilled hand for best results.

**Mini by Revopoint:** Compact and user-friendly, but mastering its potential is a challenge.


When scanning living entities, IR-based scanners are essential due to safety concerns. Laser scanners, though powerful, come with their own set of challenges, like the need for markers for precise tracking.

For unparalleled accuracy, meteorological scanners are the elite choice. The FreeScan Combo by Shining3D is one of the best scanners with a combination of both IR and laser for more possibilities. Their precision is unmatched, but they also demand a deep understanding to harness their full potential.

<ArticleImage src="/posts/3d-scan-3.webp" />

## Challenges in 3D Scanning

**Reflective Surfaces:** Even with advanced devices, reflective materials, especially black ones, pose challenges. Solutions like white dusting powder and additional markers are not always foolproof.


**Exposure Control:** Bright environments can compromise scan quality, even with top-tier devices.


**Mesh Issues:** A ubiquitous concern, no scanner is entirely free from this issue.

## Solution

At Mekuva, we've spent years mastering the art and science of 3D scanning. While the technology is accessible, achieving perfection requires a blend of experience, skill, and the right tools. Our dedicated team is trained to handle the nuances and challenges of 3D scanning, ensuring you get impeccable results every time.

Instead of navigating the complexities yourself, why not leverage our **expertise**? Equipped with the latest scanners and essential software, we're your one-stop solution for all 3D scanning needs. Reach out to us at [contactus@mekuva.com](mailto:contactus@mekuva.com?subject=Product%20%2F%20Service%20Inquiry), and our team will provide a solution tailored just for you, saving you time, effort, and potential pitfalls.


3D Printing Unveiled:A Beginner's Guide

Behind the Scenes:The Sequential Stages of 3D printing

Navigating 3D Printing Spectrum:A Closer Look at 3D Printing Classification

Revolution Vs Tradition

Revolutionizing Manufacturing- The Power of Binder Jetting 3D Printing

Perfecting Your Prints:The Art of Post-Processing in 3D printing

Comprehensive Insights into Laser Cutting Manufacturing Techniques

3D Scanners - Why Expertise Matters in Digital Replication

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