BASICS OF 3D PRINTING TECHNOLOGIES & TYPES

 Material Extrusion—Extrusion is the process of selectively dispensing material via a nozzle

or aperture in layers. Plastic, nylon, FDM, FF, and sand are among of the materials used.
o Types : Fused deposition modeling (FDM is a registered trademark of the process
developed by Stratasys Inc.) It is often called fused filament fabrication (FFF) if the
filament is used as the material.
Materials: Plastic filaments encompass a variety of materials such as PLA, ABS, PET, PETG,
TPU, nylon, ASA, PC, HIPS, carbon fiber, and more. Innovative materials containing metal
fillers are now available, which are incorporated within the extruded plastic "rods."

2. Vat Photopolymerization—Pre-deposited photopolymers undergo a selective curing process,

facilitated by the light-activated cross-linking of adjacent polymer chains. This intricate
procedure incorporates the use of photopolymers as the primary material, resulting in the
formation of stable and intricately connected structures.
o Types: SLA, MSLA μSLA and more.
o Materials: Photopolymer resins (castable, transparent, industrial, biocompatible etc.)

3. Powder Bed Fusion—utilizing thermal energy, specific areas within a powder bed are selectively
fused. The materials employed in this process encompass metals, polymers, and fibers.
o Types: Selective laser sintering (SLS), selective laser melting (SLM), electron beam
melting (EBM), direct metal laser sintering (DMLS), Multi Jet Fusion (MJF)
o Materials: Thermoplastic powders (Nylon 6, Nylon 11, Nylon 12, etc.), metal powders
(steel, titanium, aluminum, cobalt, etc.), ceramic powders

Figure: 3D Printing Technologies

4. Material Jetting—Material Jetting is a captivating process where carefully deposited droplets
coalesce to form intricate objects. The technique employs a diverse range of materials, including
mesmerizing photopolymers, malleable wax, granular sand, and versatile poly-jetting substances,
ultimately giving life to a stunning array of creations.
o Types: Material Jetting (MJ), Drop on Demand (DOD)
o Materials: Photopolymer resin (Standard, Castable, Transparent, High Temperature). It
include: rigid (various colors), flexible (rubber-like from 30 to 90 Shore A), transparent
(lens/window quality), and biocompatible options.

Figure: Outline of seven types of the 3D printing technologies and their functional processes

5. Binder Jetting — The approach entails the careful application of liquid bonding agents to
powdered components. These materials include metal, plastic, ceramic, and sand.
o Types: Metal Binder Jetting, Sand Binder Jetting.
o Materials: Sand, polymer, or metal powder: Stainless / Bronze, Full-color sand,
Silicia (sand casting); Ceramic-Metal composites
6. Directed Energy Deposition —DED uses concentrated heat energy to fuse materials as they are
deposited. Wire and powder are among the materials used.
o Types: Laser Engineered Net Shaping (LENS); Electron Beam Additive Manufacturing
(EBAM); Cold Spray
o Materials: Metals, in wire and powder form
7. Sheet Lamination—A model is formed by bonding sheets of material together. Metal, paper,
wood, and plastic are some of the materials used.
o Types: Laminated Object Manufacturing (LOM), Ultrasonic Consolidation (UC)
o Materials: Paper, polymer, and metal in sheet forms
 Introduction to Liquid-Based 3D Printing

Liquid based 3D Printing processes utilize liquid as the primary medium (raw material) to create the
part or prototype and categorized as:
• Photo polymerization techniques: Stereolithography (SLA), Digital light processing (DLP), Liquid
crystal display (LCD), Continuous Liquid Interface Printing (CLIP)
• Material jetting techniques: Continuous Ink Jetting (CIJ), Drop on demand (DoD)
• Direct Ink writing (DIW)

PRINCIPLE OF PHOTO POLYMERIZATION

In photo polymerization, a light-sensitive resin called a photopolymer is used. This resin is placed in a
vat container. Then, it's exposed to either visible or UV light. When this light strikes on the resin, it
starts a chemical reaction called polymerization. This reaction causes the resin to turn into a solid by
forming chains or cross links. In the resin, there are monomers, oligomers, and photo initiators.
When the light hits the photo initiators, they release reactive substances that help form chains
between the monomers and oligomers.

Figure: Liquid photopolymer (on the left), induced polymerization by light (small circle—monomer, large
circle—oligomer, star—photo initiator)
This process is irreversible, meaning once the chains form; the resin can't go back to being a liquid.
By using this process, layers of resin are gradually built up to create the final product from a sliced
STL file.

1. VAT Polymerization

Vat polymerization is a fascinating 3D printing technique that uses a concentrated light source to
selectively harden a photopolymer resin contained in a vat. To solidify a thin covering of liquid
plastic, light is focused at certain spots. The method is performed layer by layer until the desired 3D
item is created.
Stereolithography (SLA), digital light processing (DLP), and masked Stereolithography are the three
most used methods of vat polymerization (MSLA). Although each of these 3D printing technologies
operates on the same core assumption, the primary distinction is the type of light source utilized to
cure the resin. Understanding the distinctions between various light sources is critical for
determining the optimal option for a specific application.
 Figure: Vat Polymerization 3D Printing Process

Photopolymers, a unique type of resin, serve as the printing medium for all vat photopolymerization
printers. These special materials possess the remarkable ability to rapidly bond together and solidify
when exposed to certain wavelengths of light. This process, called photopolymerization, is the driving
force behind this 3D printing method.
Most vat photopolymerization printers use a container or vat to store the liquid photopolymer, with
the build platform partially immersed on the liquid's surface. Using data from a CAD file, the printer
controls a light source to selectively cure the liquid photopolymer, changing it into a solid layer. After
each layer is generated, the construction platform is re-submerged in the leftover resin, and the
process is repeated for the next layers. This cycle continues until the entire design is lovingly brought
to life, layer by layer.

STEREOLITHOGRAPHY (SLA)

Stereolithography (SLA) is an additive manufacturing process that revolutionized the world of rapid
prototyping and 3D printing. It was one of the earliest techniques developed and remains a popular
choice for creating intricate, high-resolution models and prototypes. SLA uses photopolymerization
to convert liquid photopolymer resins into solid 3D objects layer by layer using ultraviolet (UV) light.
This method offers exceptional precision and detail making it ideal for a wide range of applications
from product design and engineering to medical and dental industries.
 2. Components

1) Laser Source

The Laser Source

urce emits a precise laser beam, which is directed onto the liquid resin in the container.
This laser is a critical component in the solidification process, as it selectively cures and hardens the
liquid resin layer by layer, ultimately forming the desired 3D object.

2) Container

The Container is filled with liquid resin, serving as the raw material for creating the part. When the
focused laser beam interacts with the liquid resin, it initiates the solidification process. This precise
interaction between laser and resin is the foun dation of Stereolithography's layer-by-layer
foundation layer
construction.

3) Platform

The Platform in the Stereolithography Machine is an integral part of the part

part-building process. It
possesses the capability to move both upward and downward. During the construction of a part, the
Platform descends incrementally after the laser solidifies each layer. This controlled movement
allows new layers of liquid resin to be added and solidified on top of the previously formed solid
layer. The precision and accuracy of the Platform's movement are essential for producing detailed
and dimensionally accuratete 3D objects in the Stereolithography process.

Figure: Stereolithography
 3. Steps involved in SLA Process

Step 1: prepare the 3d model

Step 2: Slice the model use slicer software
Step 3: set up the SLA printer
Step 4: Initiate the printing process
Step 5: Resin solidification
Step 6: platform movement layer by layer
Step 7: Post curing

Step 1: start by designing or obtaining a 3d model of the using CAD software such as NX-CAD, Solid
works etc. This 3D model converted into compatible file format such as .STL or .OBJ , 3MF.

Step 2: Slice the model use slicer software to divide the 3d model into thin horizontal layers to
determine the path of the printer so as to create the object layer by layer.

Step 3: set up the SLA printer - Make sure the printer is calibrated and filled with the correct resin.
Ensure the build platform is clean and properly leveled before printing.

Step 4: Initiate the printing process: Load the sliced file into the printer's software. Adjust settings
like layer height, speed, and add support structures to begin the process.

Step 5: Resin solidification - The SLA printer uses a UV laser to solidify thin layers of liquid resin. The
laser traces each layer's pattern onto the resin surface according to the model.

Step 6: The build platform moves after each layer is solidified. This process repeats until the entire
object is printed.

Step 7: Wash off uncured resin with isopropyl alcohol (IPA). Strengthen parts with a post-curing
process if needed. Remove supports and sand the parts for a smooth surface. SLA parts can be
machined, primed, painted, and assembled as required.

4. Advantages of Stereolithography Process

 High precision and fine detail in the final product.

 Smooth surface finish, reducing the need for post-processing.
 Versatility in creating intricate and complex geometries.
 Supports a wide range of materials for different applications.
 Rapid prototyping enables quick design iteration.
 5. Disadvantages of Stereolithography Process

 Limited in building large-sized objects.

 Post-processing may be required to remove excess resin and achieve desired aesthetics.
 Material choices are often limited compared to other 3D printing methods.
 Handling liquid resins can be messy and require safety precautions.
 Stereolithography machines tend to be relatively expensive.

6. Applications of Stereolithography Process

 Prototyping and product development

 Medical and dental models
 Custom jewelry and fashion accessories
 Architectural models
 Art and sculptures
 Rapid tooling and manufacturing aids
 Educational models
 Engineering and aerospace components
 Consumer electronics components

SLA MODELS & SPECIFICATIONS

Stereolithography (SLA) 3D printers come in a variety of models, each with different specifications
that cater to various applications, such as prototyping, dental, jewelry, engineering, and industrial
uses. Here are some popular SLA 3D printer models, along with their key specifications:

1. Formlabs Form 3+

 Build Volume: 145 × 145 × 185 mm (5.7 × 5.7 × 7.3 inches)

 XY Resolution: 25 microns
 Layer Thickness: 25 - 300 microns
 Laser Power: 250 mW
 Laser Type: 405 nm, Class 1 laser
 Scanner Type: Galvanometer-based
 Materials: Standard, engineering, dental, biocompatible, and jewelry resins

2. Peopoly Phenom L

 Build Volume: 345 × 194 × 400 mm (13.6 × 7.7 × 15.7 inches)

 XY Resolution: 72 microns
 Layer Thickness: 30 - 100 microns
 Light Source: 405 nm UV LED array
 Scanner Type: LCD Masking Technology (MSLA)
  Materials: Standard, engineering, high-temperature, and castable resins

3. 3D Systems ProJet 6000 HD

 Build Volume: 250 × 250 × 250 mm (10 × 10 × 10 inches)

 XY Resolution: 65 microns
 Layer Thickness: 25 - 100 microns
 Laser Power: 1,000 mW
 Laser Type: 405 nm solid-state laser
 Scanner Type: Galvanometer-based
 Materials: Standard, high-temperature, and specialty resins (e.g., flexible, biocompatible)

4. Formlabs Form 3L

 Build Volume: 335 × 200 × 300 mm (13.2 × 7.9 × 11.8 inches)

 XY Resolution: 25 microns
 Layer Thickness: 25 - 300 microns
 Laser Power: 2 × 250 mW lasers
 Laser Type: 405 nm, Class 1 laser
 Scanner Type: Galvanometer-based
 Materials: Standard, engineering, dental, and specialty resins

PHOTOPOLYMERS USED IN STEREOLITHOGRAPHY

There are many types of liquid photopolymers that can be solidified by exposure to electro-
magnetic radiation, including wavelengths in the gamma rays, X-rays, UV and visible range, or
electron-beam (EB). Most photopolymers used in the commercial RP systems, including 3D
Systems SLA machines are curable in the UV range. UV-curable photopolymers are resins which
are formulated from photo initiators and reactive liquid monomers. There are a large variety of
them, and some may contain fillers and other chemical modifiers to meet specified chemical and
mechanical requirements. The process through which photopolymers are cured is referred to as
the photopolymerization process.

Some types of photopolymers used in Stereolithography (SLA) and other 3D printing methods:
 Acrylate-based polymers
These include polyhydroxymethyl methacrylate (pHEMA), polyethylene glycol diacrylate (PEGDA),
and polymethyl methacrylate (PMMA).
 Epoxy-based polymers
These are used for printing parts that need to withstand high temperatures.
 Polyurethane-based polymers
These are used for applications that require flexibility and elasticity, such as footwear.
Photopolymers can be categorized into five types based on chemical reaction
Type -1 Photo initiated radical, cationic or anionic chain polymerization
Type -2 Step growth reactions
Type- 3 Photo induced cross-linking between X and Y
Type-4 Deep- seated photochemical reaction modification
Type-5 Photo induced cleavage reaction

LAYERING TECHNOLOGY

1. Top-Feeding Technique

 Definition: The build platform is positioned at the top of the resin vat, and the object is pulled
upward as it is printed, layer by layer.
 Common Technologies: Found mostly in traditional SLA and some DLP 3D printers.

Process:

 The build platform starts at the top of the resin vat.

 The UV laser or light source cures each layer of resin.
 After each layer is cured, the platform lifts upward, exposing a fresh layer of liquid resin for
the next layer to be formed.

Advantages:

 Clear Resin Flow: The resin naturally fills in below the object as it lifts, so there’s no need for
mechanisms to ensure resin flow.
 Less Mechanical Complexity: The vat remains stationary, and only the build platform moves.

Disadvantages:

 Increased Print Time: The lifting process takes more time as the object has to be raised
incrementally for each layer.
 Potential for Higher Resin Use: A larger vat of resin is required to ensure consistent coverage,
even for small parts.

2. Bottom-Feeding Technique (also called Inverted SLA):

 Definition: The build platform starts at the bottom of the vat, and the object is pulled
downward or inverted as it prints.
 Common Technologies: This is often used in inverted SLA and DLP printers, where the light
source is positioned underneath the resin vat.
 Figure: Layering Technologies

Process:

 The build platform is submerged at the bottom of the resin vat.

 A UV laser or light source from below the vat cures each layer of resin.
 ured, the platform lifts slightly, allowing the next layer of resin to fill the
After each layer is cured,
space and be cured.

Advantages:

 Less Resin Required:: Only a thin layer of resin needs to be present in the vat, reducing
material waste.
 Faster Print Time:: The platform lifts a short distance between layers, leading to quicker layer
formation.
 Reduced Vat Size:: The resin vat can be much smaller, making it ideal for desktop printers.

Disadvantages:

 Peeling Forces:: As the platform lifts after each layer, the cured layer must peel off the bottom
non stick surface). This peeling can sometimes cause issues with delicate
of the vat (usually a non-stick
or thin features.
 Potential for Resin Spreading Issues ckly into the gap between the
Issues: Resin has to flow quickly
platform and the bottom of the vat, which can cause uneven layer formation if the resin is too
viscous.
Key Differences Between Top-Feeding and Bottom-Feeding:

 Material Use: Bottom-feeding uses less resin overall compared to top-feeding, making it
more efficient for smaller parts.
 Build Speed: Bottom-feeding is generally faster due to shorter movement distances and
smaller resin volumes.
 Complexity: Top-feeding is simpler mechanically, while bottom-feeding often requires special
coatings on the vat and careful calibration to prevent peeling issues.

LASER AND LASER SCANNING

In Stereolithography (SLA), lasers and laser scanning are critical components for accurately curing
resin and creating precise 3D prints.

 Laser in SLA

 Definition: A laser is a concentrated beam of ultraviolet (UV) light used to cure (solidify) a
liquid photopolymer resin.
 Purpose: The laser’s role is to selectively harden the liquid resin, building up the 3D object
layer by layer.

Types of Lasers Used:

 UV Lasers (Commonly 405 nm wavelength): These are typically used in SLA printers because
the resin is formulated to cure when exposed to UV light.
 Diode Lasers: Some SLA printers use diode lasers due to their energy efficiency, precision, and
ability to create fine details.

 Laser Scanning in SLA

 Definition: Laser scanning refers to the controlled movement of the laser beam across the
resin surface to trace and cure each layer of the object.
 Purpose: The laser selectively cures the resin in the exact pattern needed for each layer,
corresponding to the design of the 3D model.

Working of Laser Scanning

 Galvanometer Mirrors: A system of fast-moving mirrors, called galvanometers or galvos,

controls the direction of the laser beam. These mirrors tilt at precise angles to guide the laser
over the resin surface.
o X and Y-axis movement: The mirrors direct the laser in the X and Y directions, allowing
the laser to follow the contours of the desired shape for each layer.
 Flying liquid: refers to the dynamics of the liquid photopolymer resin during
dur the SLA printing
process, particularly how the liquid resin behaves when interacting with the laser or when the
platform moves.

 Flying Optics: Refers to the movement of the laser beam via mirrors (galvanometers) in a
up. This system ensures precise and fast laser scanning across the print
stationary laser setup.
surface, maintaining high accuracy and consistency.

 Digital Light Processing (DLP) based 3D printing process where a

(DLP): DLP is a photopolymer-based
ts light patterns (usually UV light) onto the surface of a liquid resin, curing
digital projector casts
entire layers at once.