Winter 2024 ENGG 6290-04 Advanced Manufacturing Project Report

Project Report for 3D Printing

Progress Report presented to:
Dr. Abdelkrem Eltaggaz

On
March 15th, 2024

Submitted by:
Krishna Khurana (Student ID: 1307672)
Vaibhav (Student ID: 1306821)
Hari (Student ID: 1306821)
Jenish (Student ID: 1306821)
Jyoshna Bhoomireddygari (Student ID: 1303742)

University of Guelph, Engineering Department

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 Winter 2024 ENGG 6290-04 Advanced Manufacturing Project Report

INDEX
[Link]. Contents Page No.

1 Introduction

2 Case Study

3 Methodology

4 Part quality and defects

5 Opinion & suggestion

6 Mastercam Project

7 References

Introduction
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 Winter 2024 ENGG 6290-04 Advanced Manufacturing Project Report

Additive manufacturing, commonly referred to as 3D printing, has completely changed production

procedures in several different sectors. In contrast to traditional subtractive methods used in
traditional manufacturing processes, 3D printing creates products layer by layer from a digital
design, providing unmatched flexibility and efficiency. This report examines the developments,
uses, and potential of 3D printing technology.

3D printing was first introduced in the 1980s by academics in the United States, France, and Japan.
Chuck Hull of 3D Systems Corporation was the first person to receive a patent for 3D printing in 1
984, which set the stage for further advancements.
His stereolithography process which uses UV light to gradually develop photopolymers—
remains an essential component of additive manufacturing.
Classification of Additive Manufacturing Processes:

1. Vat Photopolymerization: This process produces prints with excellent resolution by using
UV light to harden liquid photopolymer resin.
2. Material Jetting: A technique that allows for multimaterial printing by depositing droplets
of photopolymer or materials like wax into a construction material.
3. Binder Jetting: A liquid binder is used to selectively bond powdered materials; ideal for qu
ick prototyping.
4. Material Extrusion: Because of its affordability and adaptability,
the thermoplastic filament is fused through a nozzle that is heated in this commonly used
process.
5. Powder Bed Fusion:
i. Selective Laser Sintering (SLS): Using a laser to fuse powdered material, it is a
perfect example for complicated geometries.
ii. Selective Laser Melting (SLM): Using a laser to completely melt metal powder, s
olid, strong pieces are produced.
iii. Electron Beam Melting (EBM):- Using an electron beam, provides for the
scalability of melting metal powder for large portions.
6. Sheet lamination: This method, which works well for big parts and composites, adheres
sheets of material together with heat or glue.
7. Directed Energy Deposition: This process is useful for adding material or mending
damaged sections, and involves depositing material into a base material using
concentrated energy sources like lasers or electron beams.

Applications and Materials:

3D printing has applications in several industries, including consumer products, consumer goods, a
utomotive, and aerospace.
Food, biological materials, metals, and polymers are all employed in 3D printing. Strong and long-
lasting metals like titanium, aluminum, and stainless steel are preferred, while biocompatible mater
ials like Nitinol have potential use in the medical implant industry.

Limitations of 3D printing:

3D printing has some drawbacks.

Constrained materials, surface quality problems (rough surfaces, layer lines), difficulties reaching
high resolution and accuracy, relatively slow printing speeds, the requirement for labor-intensive s
upport structures, size restrictions due to printer build volumes, total cost considerations (materials,
equipment, and post-processing), possible differences in material properties from traditional manuf
acturing, environmental concerns about waste management and material safety, and intellectual pr
operty issues associated with digital replication are some of these.
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 Winter 2024 ENGG 6290-04 Advanced Manufacturing Project Report

To fully realize the promise of 3D printing across sectors and minimize related downsides, these
constraints must be addressed through further research and development initiatives.

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 Winter 2024 ENGG 6290-04 Advanced Manufacturing Project Report

Case Study

Title: 3D Printing Aeroplane Model

An airplane model is a scaled-down version of an actual aircraft, typically used for testing aerody
namics, presentation, or education.
In a more compact form factor, it simulates the layout and characteristics of a full-sized aircraft.
Models of airplanes may be as basic as static ones or as detailed as dynamic ones with moving co
mponents and complex interiors.

Advantages of Selecting Aeroplane Models for 3D Printing:

There are several benefits and potential when selecting an airplane model for 3D printing:

Visualization and Education: By producing very exact and accurate models of airplanes, 3D print
ing enables experts, individuals, and students to have a concrete understanding of the structure an
d operation of aircraft.

Personalization: By utilizing 3D printing, airplane models may be altered to imitate certain aircra
ft models, encompassing changes in features, livery, and [Link] of this customization, one
may create distinctive models that are customized to meet project needs or individual preferences
.

Testing and Prototyping: 3D-printed airplane models may be used as test subjects for design vali
dation and aerodynamic [Link] fullscale production, engineers and researchers may analy
ze the dynamics of airflow, compare the performance of various configurations, and optimize airp
lane designs.

Training and Simulation: By using 3Dprinted aircraft models, pilots, engineers, and maintenance
staff may receive practical experience in aircraft operation, maintenance, and repair techniques.

CostEffectiveness: 3D printing makes producing airplane models more affordable when com
pared to conventional manufacturing techniques, particularly for low-volume or customized
designs. This cost makes high.

Overall, choosing an airplane model for 3D printing offers a chance to take use of
additive manufacturing technology's potential to produce precise, adaptable, and
reasonably priced models of aircraft for a range of uses and sectors. Change up the
heading styles and provide more context for our decision-making
quality aircraft models aremore widely available to museums, educational organizations, and enth
usiasts.

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Winter 2024 ENGG 6290-04 Advanced Manufacturing Project Report

Interviewees: -