Unit-2

CAD Modelling for 3D Printing

1. Introduction to 3D Printing
Definition: 3D printing, also known as additive manufacturing, is the
process of creating three-dimensional objects from a digital file by
adding material layer by layer.
History: Developed in the 1980s, 3D printing has evolved from simple
prototypes to complex manufacturing processes used in various
industries, including healthcare, automotive, and aerospace.
How It Works: The process typically involves:
Creating a 3D model using CAD software.
Converting the model into a format suitable for printing.
Slicing the model into layers.
Printing the object layer by layer.
2. 3D Scanning and Digitization
3D Scanning: A method used to capture the physical dimensions of an object. It
creates a digital model by recording the shape and surface details.
Types of Scanners: Laser scanners, structured light scanners, and
photogrammetry.
 Digitization: The process of
converting physical objects
into digital data. This can
involve:
Scanning an object to
create a 3D model.
Using software to refine
the model for printing.
3. AM Software: Data Formats
Common Data Formats:
STL (Stereolithography): The most widely used format for 3D printing. Represents the
surface geometry of a 3D object using triangles.
OBJ: Includes color and texture information, suitable for more complex models.
AMF (Additive Manufacturing File Format): A newer format that supports advanced
features like colors and multiple materials.
Advantages and Limitations of STL:
Advantages:
Widely supported across different 3D printers.
Simple and efficient for geometric representation.
Limitations:
No support for color or texture.
Can result in large file sizes for complex models.
Does not support curved surfaces accurately.
4. Creating an STL File
Steps to Create an STL File:
Model Creation: Use CAD software (like AutoCAD,
SolidWorks, or Tinkercad) to create the 3D model.
Exporting: Select the option to export or save the model as
an STL file.
Checking for Errors: Use software to check the STL file for
any errors, such as non-manifold edges or holes.
Optimization: Ensure the model is optimized for printing
(size, scale, and complexity).
5. Slicing
What is Slicing?: The process of dividing a 3D model into horizontal
layers for printing. This step is crucial for translating a 3D model into
instructions that a 3D printer can understand.
Slicing Techniques:
Uniform Flat Layer Slicing: Each layer is of the same thickness,
which is easy to calculate and implement but may not optimize
material usage or printing time.
Adaptive Slicing:
geometry, allowing for faster printing of simple areas and more
detail in complex regions
6. Process-Path Generation
Rasterization: Converting the 3D model into a 2D path that the printer
can follow. This involves determining the movement of the print head or
nozzle.
Part Orientation: The angle and position at which the part is printed.
Correct orientation can enhance strength and reduce the need for
support structures.
 Support Generation: Structures added to support overhangs and
complex geometries during printing. These can be removed after
printing, but they need to be designed carefully to avoid damaging the
printed part.
 3D Printing
Additive manufacturing is the opposite of subtractive
manufacturing which was used widely in the past involving gradual
removal of layers from a solid block of any material either be wood or
metal to form a 3D object.
Additive manufacturing as the name indicates is the layer by layer
deposition of a specific material to form a 3D shape or structure.
This technique can be employed in powders be it glass, ceramic,
metal and resins in liquid form.
Complex shapes and design elements can be easily cured on the
materials using additive manufacturing techniques.
There is almost zero wastage of the raw material in the additive
manufacturing process.
A narrow range of materials can be employed for the process which
has relatively low melting points.
 SLA- Stereolithography
The term Stereolithography was coined by Chuck Hill in 1984.
SLA is also called VAT Polymerization.
SLA process involves the production of a 3D model by casting a light
beam on the photopolymer resins.
When the UV light beam strikes the polymer layer, it castes a design
on the polymer bed, the design then solidifies and moves one inch
downward, afterwards another sheet is polymerized in the same
way, the process continues until the 3D object is formed completely.
After the competition, the modeled object is washed with the
solvent to remove excess resin from the layers making the design
neat and sleek.
This process is highly expensive yet fast, you can generate your
model in a day.
 SLA- Stereolithography

[Link]
 FDM- Fused Deposition Modelling
It is the most commonly used method of 3D printing these days.
FDM is used for the production of 3D prototypes and small-scale end products as
well.
Thermoplastic material like Polyacetic acid is used in the process as the core
material.
A 3D object is printed in layers by heating the thermoplastic material and
extruding it on the layers by extrusion nozzles.
The liquefier head along with the extrusion nozzles moves in X and Y coordinates
according to the instructions already fed into the printer depending on the design
of the 3D object.
Each layer when formed is consolidated with the layer beneath it which hardens
by time.
The Fused Deposition Model is quick and produces sturdy 3D products with sleek
finishing.
[Link]
 LOM- Laminated Object Manufacturing
As the name suggests, laminated object Manufacturing makes
use of laminated sheets coated with adhesive material.
The sheets can be made of plastic or paper according to the
requirement of the 3D model.
All the laminated sheets are glued together under specific
temperatures and pressure.
The laminated sheets are then cut into the desired 3D shape
with the help of a laser or anything other cutting-edge
technology.
This is one of the outdated methods of 3D printing which aren't
used today.
[Link]
What is CNC Machining?
Definition: CNC (Computer Numerical Control) machining is a subtractive
manufacturing process that uses computerized controls and machine tools to
automate the fabrication of parts. Pre-programmed software dictates the
movement of machinery and tools, enabling precision and efficiency in shaping
metal, plastic, and other materials.

Key Components of CNC Machining Process:

CAD (Computer-Aided Design): Designing the part using software.

CAM (Computer-Aided Manufacturing): Converting CAD models to machine
instructions.
CNC Machine: Performs the material removal.
Diagram: A flowchart showing the CNC process from design to finished product
1. Advantages of CNC Machining

High Precision and Accuracy: CNC machines can work with tight tolerances
(±0.001 mm) for complex parts.
Consistency and Repeatability: Once a part is programmed, it can be
replicated with identical accuracy.
Automation: Minimal manual intervention; reduces errors and allows for 24/7
manufacturing.
Efficiency: Optimized tool paths, automatic tool changes, and minimal
downtime.
Complex Geometries: Multi-axis capabilities (up to 5-axis) allow CNC
machines to create intricate designs that are impossible with manual
machining.
Reduced Waste: More efficient material usage compared to traditional
methods.
Scalability: Ideal for both prototyping and mass production.
1. Limitations of CNC Machining

High Setup Costs: CNC machines are expensive, with initial setup including
hardware, software, and tooling investment.
Complex Programming: Requires skilled technicians familiar with G-code, M-
code, and CAD/CAM software.
Time-Consuming for Low Volume: For small batches, the setup time may
outweigh the benefits of CNC machining.
Maintenance and Tooling Costs: Requires regular maintenance and tool wear
management.
Material Limitations: While CNC works well with metals and plastics, some
materials like certain composites or ceramics may be challenging.
Types of CNC Machines
CNC Milling Machines:
Function: Rotating cutting tools move along multiple axes to remove material.
Applications: Complex parts, molds, dies, and 3D shapes.
Types of CNC Machines
CNC Lathes:
Function: Rotates the workpiece while stationary cutting tools remove material.
Applications: Cylindrical parts, shafts, bushings.
CNC Routers:
Function: High-speed cutters for softer materials (wood, plastic, foam).
Applications: Furniture, signage, and custom products.
CNC EDM (Electrical Discharge Machining):
Function: Uses electrical sparks to erode material, typically for hard
metals.
Applications: Tooling, dies, and complex geometries with high hardness.
Major Components of a CNC Machine

Controller (CNC Control Unit): Processes G-code and M-code commands to

control the machine's movement and operation.
Spindle: The rotating part of the CNC machine that holds the cutting tool or
workpiece.
Axes (X, Y, Z + Optional Rotational Axes): Control the movement of the tool
and/or workpiece. In a 5-axis machine, two additional rotational axes (A, B, or C)
allow for complex part geometry.
Automatic Tool Changer (ATC): Automatically switches between tools without
stopping the process, increasing efficiency.
Workholding Devices (Chucks, Vices): Hold the material in place securely while
machining.
Servo Motors and Drives: Responsible for the precise movement of machine
axes.
Diagram: A detailed diagram of a CNC machine, with each component labeled
(controller, spindle, axes, ATC, motors).
CNC Machine Configurations
3-Axis Machines:
Movement in X, Y, and Z directions (up, down, left, right, forward, and back).
Suitable for flat and basic 3D designs.
4-Axis Machines:
Adds rotation around one axis (often the X-axis) for increased flexibility.
Useful for parts that require machining on multiple sides.
5-Axis Machines:
Adds two rotational axes (around X and Y, or X and Z).
Can create extremely complex geometries, such as aerospace components,
turbine blades, and medical devices.
Diagram: Illustration comparing 3-axis, 4-axis, and 5-axis machine configurations.
1. Introduction to G-Code
Definition: G-code (Geometric Code) is a numerical control programming
language that dictates the movement of the machine's tool or workpiece. It
describes how and where the machine should move (positioning), the speed of
movement (feed rate), and the toolpath for machining.
Syntax: G followed by a number, representing different commands.
Examples: G00 (Rapid positioning), G01 (Linear interpolation), G02 (Circular
interpolation - CW), etc.

2. Introduction to M-Code
Definition: M-code (Miscellaneous Code) controls various machine operations
that are not related to tool movement. These include starting and stopping the
spindle, changing tools, or turning the coolant on/off.
Syntax: M followed by a number, representing different machine functions.
Examples: M03 (Spindle on - CW), M06 (Tool change), M08 (Coolant on), etc.
Important G-code Commands and Their Functions:
Important G-code Commands and Their Functions:
Important G-code Commands and Their Functions:
4. Detailed G-Code Example for a Machined Part
Objective: Create a 100mm x 50mm rectangular pocket with a depth of
10mm.
Program:
M-code (Miscellaneous Code)

Definition: M-code handles machine-specific operations that are not

related to the path or geometry of the tool. It controls functions such as
starting/stopping the spindle, turning the coolant on/off, and managing tool
changes.
Format: Typically starts with the letter "M" followed by a number. E.g.,
M03, M06, M30.
Common M-Code Commands and Their Functions
Common M-Code Commands and Their Functions
Applications of CNC Machining

CNC Programming Example

Part Example: Create a simple block with a drilled hole.
Programming Sequence:
G00 X0 Y0 Z0: Rapid move to start position.
G01 X100 Y50 F200: Linear cutting to specified coordinates.
G02 X100 Y100 I50 J0: Circular interpolation for a drilled hole.
M06: Tool change for different cutting operations.
M30: End of program.
Applications of CNC Machining
Automotive Industry:
Engine components, transmission parts, custom gears.
Aerospace Industry:
Aircraft structural components, turbine blades, fuel systems.
Medical Industry:
Custom prosthetics, surgical tools, medical implants.
Electronics Industry:
Housings for electronics, PCB fabrication, enclosures.