A Survey on the Capacity for 3d Printing to Produce Objects With a Complex Internal Structure and an Investigation of Its Potential Applications, Research Proposal Example

Introduction

The technology for printing three dimensional (3D) objects from digital data was initially developed by Charles Hull in 1984 and he named the technique ‘Stereolithography’, but a patent for the technique was not obtained until 1986 (De Leon & Winek, 2009). He later developed the first commercial 3D printing machine, which was called a Stereolithography Apparatus, and the machine was improved upon based on customer ratings to become the SLA-250, which was made available to the general public in 1988 (De Leon & Winek, 2009). The technology was further developed by Massachusetts Institute of Technology (MIT) in 1993 with their patenting of their “3 Dimensional Printing techniques”, which was akin to the inkjet technology used in 2D printers and an exclusive license from MIT was purchased by Z Corporation in 1995 for the use of the technology in the development of 3D Printers based on 3DP technology (De Leon & Winek, 2009). The technology known as 3D printers are machines that create a physical 3D model of an object based on the digital information and form an image layer by layer (De Leon & Winek, 2009). This allows users to make physical models of objects that are designed with a CAD program or copied with a 3D scanner and it can be used in numerous industries including architecture, medical, automotive, education and consumer products (Torres, Sta?kiewicz, ?nie?y?ski, Drop, & Maciejewski, 2011).

As detailed by Torres et al. (2011),

“…in 1996, three major products, “Genisys” from Stratasys, “Actua 2100” from 3D Systems and “Z402” from Z Corporation, were introduced. It was only during this period, the term “3D Printer” was first used to refer rapid prototyping machines. During the late 1990s and early 2000s, several relatively low-cost 3D Printers came into the market. In 2005, Z Corp. launched a breakthrough product, named Spectrum Z510, which was the first high definition color 3D Printer in the market. Another breakthrough in 3D Printing occurred in 2006 with the initiation of an open source project, named Reprap, which was aimed at developing a self-replicating 3D printer. The first version of Reprap, which was released in 2008, can manufacture about 50 percent of its own parts. The second version of Reprap is currently under development” (pp.1-2).

The predominant technologies used in 3D Printers include Stereolithography (SL), Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), 3 Dimensional Printing (3DP), Polyjet, and the Polyjet Matrix (Torres et al., 2011). Stereolithography uses an ultraviolet (UV) laser, a build platform, and a liquid photopolymer and it replicates the 3D CAD model divided into several thin layers using specialized software, and then sends the data to the machine (Leukers, 2005). The UV laser draws the first layer on the surface of photopolymer, solidifying it onto the build platform and then the surface is recoated with the liquid photopolymer and the process repeats until all layers within the three dimensional array are built (Bradshaw, Bowyer, & Haufe, 2010). The advantages to this method are that it is more accurate, shows good feature details, and has a smooth surface finish, but the disadvantages are that the material options are limited and color models cannot be created (Bradshaw, Bowyer, & Haufe, 2010). Using the fused deposition modeling method relies on thermoplastic material to build the 3D model and is similar to stereolithography in that software initially converts the 3D CAD model into multiple thin layers and then the thermoplastic substance is provided to the extrusion head, to which heat is applied to melt the material, and then the extrusion head removes the thermoplastic material to deposits it layer by layer onto the built platform until the complete model is built (Bradshaw, Bowyer, & Haufe, 2010). The advantages include accuracy, material strength, and the use of color, but the disadvantages is that it produces a rough surface finish (Bradshaw, Bowyer, & Haufe, 2010).

The use of selective laser sintering entails the use of a CO2 (carbon dioxide) laser and a powder material that is placed over the build platform in several layers and, relying on the 3D data, the CO2 laser combines the powder material to build the model layer by layer (Allard, Sitchon, Sawatzky, & Hoppa, 2005). The advantage is in the greater material strength, but the disadvantages include diminished accuracy, the rough surface finish, and color models cannot be created (Allard et al., 2005). Three dimensional printing is founded on the use of a powder material and a liquid binder to build the model similar to method of the Selective Laser Sintering, but uses a liquid binder to bind the powder material instead of using UV laser, spraying it through the inkjet print heads like with a 2D printer (Allard et al., 2005). The advantages are that it is more accurate and can create high definition color models, but the disadvantages is that there is a reduction in the material strength, it provides a rough surface finish, and less feature detail (Allard et al., 2005). Using the Polyjet or Ployjet Matrix provides a new technology for 3D printing, which propels photopolymer material, or different materials with a Polyjet matrix, in ultra-thin layers onto a build platform and a UV light cures each layer immediately after it is jetted, which produces more accurate models with layer thickness of about 16 microns with a smooth surface finish (Allard et al., 2005). Other benefits include the increased accuracy, better feature details, and it can create color models, but the disadvantage is the decreased material strength (Allard et al., 2005).

Aims:

To completely investigate the abilities of three dimensional-printing, in order to produce a product with complex internal structures that could provide assistance and improve the way of living to the ultimate consumer, which would too contain entailing the merchandise to the specification of the purchaser demands, and also using up fewer objects, inexpensive manufacturing, co-design, and the development of resourceful opportunities.

Objective:

The whole objective is to create a comfortable chair that’s suitable for the 3d fabrication by operating a honeycomb framework foundation. Additionally, the practice of ergonomics will deliver a prototype for the product pattern to increase comfort. Moreover, a revision of the applied request of an organic project and the digital three-dimensional product is managed. Nevertheless, security and dependability demands are regulated for this specific design.

Primarily this study explored that the demand, plan, and survey of a product that’s efficient of offering help to innovative positions. In addition, to the extreme incidence of low-back pain in business potentially due to labors operating their duties while supposing forward-leaning areas along with the organic credibility of these positions producing low-back pain, the need was for created for merchandise that offers innovative locations. An envelope was quantified, ranging from the 5th percentile female to the 95^th percentile male, to form the variety of possible innovative positions (Heyne & Herrmann, n.d.). The object of a Support-Arm for use with recent ergonomic chairs was mentioned and the design element guidelines were then given. A Latin Square statistical pattern was working to evaluate a Support-Arm prototype beside eight other customarily used chairs more than three diverse areas. Participants, generally, had a lesser optimal intensity for the buttock/thigh section, that enhanced production, to a greater degree of comfort , and advanced buttock-thigh contact areas when placed in the Support-Arm model chair as contrasted to the other chairs. Studies, overall, also have rated this chair first above the other chairs for selected usage after sitting in all nine chairs. In the excess portion of this examination, within studies participants elected their own structure of the Support-Arm model chair. Subjects established the necessity to construct the Support-Arm potential of delivering forward leaning support to completely encompass the forward-leaning postures. The numerical assessment exposed many substantial diverse between the chairs. These outcomes indicated no suggestion that the use of a Support-Arm for forward-leaning support would possibly produce negative consequences to consumers and totally chair ergonomics. However, forthcoming examination could trace employees’ employment of the Support-Arm in business and connect their experience of low-back aching to a control group.

The extruded metal honeycombs [linear cellular alloys (LCAs)] are constructed for a diverse purpose that requires not only physical presentation but also intensity transference abilities. The industrial progression for LCAs permits compound in-plane cell topologies that possibly could be custom-made to accomplish preferred results of its capability. Furthermore, as the consequences develop specific motorized and heat transferal assets of LCAs are superior to individuals of hexagonal honeycombs or stochastic metal foams. Typically, a recurrent and functionally sorted LCAs are invented for a mechanical heat transfer device for an electronically refrigeration application. This particular enterprise strategy was created as a multi-objective resolution. The estimated patterns of the mechanical development and intensity of transferal operation, such as limited diversity within the intensity levels of transferal models, are working to study projects professionally. Although, a collection of heat exchanger designs is made with each episodic and functionally arranged cell topologies. Additionally transactions are measured involving thermal and physical execution. The preceding novelist, have concentrated continuously on the examination of their structural components and resources of mobile supplies and has adopted, an enterprise perspective to evaluate productivity. Perhaps, being granted with a selection of rugged thermal systematic replicas, helped underline the synthesis of mobile projects and documentation of excellent enterprise countries.

For customarily manufactured wooden furniture equipment, joint pressure is a general concern. Basically the furniture, joints symbolizes the definite fact of malfunction, and they are located exactly where the part is most expected to be unsuccessful under complete intensity. Also for human load-bearing furnishing equipment, which is a chair and it becomes a safety issue, with metal sheer in the case of metal fasteners and wood sheer in the case of dowel fasteners, joints in conservative furnishing which are ordinarily the fragile location of the construction department. We hope to evade this occurrence with our design development. One particular, purpose of this objective is to construct the chair out of a rock-hard portion of material such which is composite, graphite, wood, or metal and that’s why the prevention of joint breakdown is a usual necessity of this object.

These resources typically generate another safety standard concern, which is the potential for fire hazards. Although, the furniture was not projected to be constructed not necessarily for fire resilient but originally for fire resistant to a certain degree. For instance, in the case of a fire, no individual or person wants to be placed upon a highly combustible object. Furthermore, firefighters and fire regulators aim for more and more fire safety resources generally because they want to evade authorized responsibility for a risky product.

Rationale and Context for Research:

This research is important for many reasons both industrially and professionally. From an industrial standpoint, learning to apply new technologies to old problems is the cornerstone of innovation. The more we know how to do with materials, the better equipped we will be to invent or re-invent products. The better manufacturing processes we can develop, the better the quality of life. From a professional standpoint, it is a challenge to lead product development end-to-end. Furthermore, personal interest in emerging material and manufacture are interesting. Also, the concept of biomimicry to develop better artifacts for industry, government, and the marketplace promises to make future manufacturing more effetcive in producing well-built products. The challenge of the chair in this case includes not only the application of biomimiced technology but also the application of human user interface quality and standards.

This research is needed because it provides a starting point of application for emerging design and manufacture techniques. This is important to research manufacturers interested in applying these emerging techniques. Furninture manufacturers and consumers will benefit directly from this design. Although the manufacture of furnature itself is centuries old, the manufacturing techniques applied here promises to bring strnager, more comfortable and safer furnature. A new chic market will probably emerge.

The technique, identified as Diagnostic Radioentomology (DR) scanner is targeted to regulate the beehive material objects by utilizing the three-dimensional method (Heyne & Herrmann, n.d.). This procedure will be measured by taking a sequence of three-dimensional features and combine them to expose in this present time the complete dimensional attributes of the beehive. The main objective is to create a modern technology to gaze into the internal mechanisms of objects, without interrupting the internal structure utilizing the three-dimensional device. The purpose of this strategy is to identify and recognize what is affecting the structural deficiency of chairs. Therefore using an imaging technology called X-ray computerized tomography to examine a beehive will potentially produce a series of colored 3D photographs which over a period of time could be used to document in description what facets strengthen the object (Heyne & Herrmann, n.d.). Initially, by regulating x-ray computerized tomography manufacturing the three-dimensional method has revealed that 3d can be used to recognize specific attributes of the beehive structure that can be useful in the modeling and construction of the chair and this device can also be utilized to map the structure of other objects in the same manner. Primarily, this methodology significantly is not aggressive and does not involve modifying the objects, ordinarily utilizing the 3D method allows precise assessments of the volume of the object and all other dimensional facets.

The X-ray computerized tomography is directed over the beehive object in which the 3d device is closely spaced to the beehive. By measuring the time the phenomenal dimensions of the beehive, this can be used to strengthen the structure of the chair, which is easy considering the time it takes to use the 3D scanner to map the beehive, send the images back to the X-ray scanner, and prepare a three-dimensional model of the space of each scanned point within the beehive (Heyne & Herrmann, n.d.). This function will potentially consist of mapping thousands of chambers within the 3-dimensional beehive space that is a dimensionally somewhat accurate representation of this existing beehive object. This information can be converted to increase the quality of the images and more precisely plan and map structurally sound objects. Therefore giving assurance that this method is extremely accurate, the three-dimensional model will be capable of recognizing dangerous or potentially unsound structural models before they are built and avoid potential structural hazards. Additionally, by using the three-dimensional technique it will determine how parts integrate to create a sturdy, structurally sound chair or other objects, including buildings. Currently, scanners are being used more frequently in built and natural environment due to their high data acquisition rate, high accuracy and high spatial data density.

(Arayici, 2005).

Methodology:

During the information attainment, the 3d is used to allow the operator to perform a large number of tasks including sensor structure, data examination, data conception, data operation, and data archiving. Numerous export functions from the X-ray computerized tomography utilizing the 3D device permits the scanned data to be passed through the beehive colony to post processing information regarding the location of each cell in the hive. An industry of organized 3D systems rapidly captures information mainly for the use of researching each object first in a scan of the complete field within three-dimensional observation is horizontally established to aid merging hazards of data from the chair and scan positions regarding the beehive to aid the reason for the continuous structural failures. Also one or more additional 3d scans are formed with a greater degree of the beehive to establish a good relationship between the builder and the structural aspects regarding the construct of the chair. Scan time ranges from 25 seconds to 35 seconds being reliant on the resolution that is mandatory for safety reasons. This progression will be developed to connect the 3D arrangement to the X-ray device using the scanner to search for particular hazards that could be potentially causing structural lapses in objects.

Meanwhile, tracking the info anxiety, post dispensation is involved in the department, primarily providing a complete set of tools for quickly processing 3D scanned data for producing new ways to evaluate our structural issues. We should continuously produce modern techniques that would allow the builder to determine aspects of the model from other structures while still retaining the ability to model very fine details extremely accurately. It will permit 3d, and x-ray scans from each scanner position to be merged together in space. The three-dimensional device will compare geometric features in overlapping areas of the beehive structure to estimate the exact placement of each foundational component of the chair. This is a very precise system of supporting data that will utilize several thousands of measurements to create survey for these researches. This 3D method utilizes all the dimensions of informational facts without applying any danger to sampling the beehive with these techniques (Heyne & Herrmann, n.d.). In its approach, it will utilize a tolerance-based smoothing and which should stipulate a sturdy industrial power system and then the 3D model then can be observed, examined and modified as required. However it is possible to use an intellectual generalization procedure on the model to reduce the number of dilemmas which is pathogens and fungi infestations that surrounds their nests (Bornaz, & Rinaudo, 2004).

Outcome:

The three-dimensional printing model from digital designs will transform manufacturing and permit more ways to begin creating furnishing resources. As remarkable as it may seem I have several techniques that could potentially provide a sound structure for the design of the proposed furniture. Actually using the beehive as a model is sufficient because it has many facets that accommodate the three-dimensional model formats that could protect the chair from structural failure and increase the structural integrity. The first thing is to make the entire chair into a beehive shape with the arms the seating parts all formatted according to the structure of the hive. Next, create a comfortable create a comfortable seating foundation utilizing the three-dimensional printing technology as a blueprint to format the seat. The material that would be used for this specific model would be wood that is smoothly covered with holes so it can be attached to the chair. We should even create mechanical devices in the chair utilizing three-dimensional printers for estimating the exact specifications of the chair (Allard et al., 2005).

References

Allard, T.T., Sitchon, M.L., Sawatzky, R. & Hoppa, R.D. (2005). Use of hand-held laser scanning and 3D printing for creation of a museum exhibit. M. Mudge, N. Ryan, R. Scopigno (Editors). The 6th International Symposium on Virtual Reality, Archaeology and Cultural Heritage VAST 2005 Project Presentations. Retrieved from http://public-repository.epoch-net.org/publications/VAST2005/shortpapers/short3006.pdf

Arayici, Y. (2005). An Approach for Real World Data Modelling with the 3D Terrestrial Laser Scanner for Built Environment. School of Construction and Property Management, University of Salford, United Kingdom. Retrieved from http://usir.salford.ac.uk/11285/2/An_approach_for_3D_laser_scanning_data_modellingrevised2-1.pdf

Bradshaw, S., Bowyer, A. and Haufe, P. (2010). The intellectual property implications of low-cost 3D printing. ScriptEd, 7 (1), 5-31. Retrieved from http://opus.bath.ac.uk/18661/2/bradshaw.pdf

De Leon, J.E. & Winek, G. (2009). Incorporating rapid prototyping into the engineering design curriculum. Southwest Texas State University, Engineering Design Graphics Journal, 64(1), 18-23. Retrieved from http://www.edgj.org/index.php/EDGJ/article/viewFile/139/135

Heyne, M. & Herrmann, J. (n.d.). 3D printing: Taking flight one layer at a time. Retrieved from http://136.142.82.187/eng12/history/spring2012/pdf/2284.pdf

Leukers, B. et al. (2005). Hydroxyapatite scaffolds for bone tissue engineering made by 3D printing. Journal of Materials Science: Materials in Medicine, 16, 1121-1124. Retrieved from http://www.biologie.uni-r.de/Anatomie/Minuth/PDF/Proceedings/2005_Leukers-b.pdf

Torres, K., Sta?kiewicz, G., ?nie?y?ski, M., Drop, A., & Maciejewski, R. (2011). Application of rapid prototyping techniques for modelling of anatomical structures in medical training and education. Folia Morphol., 70(1), 1–4.