Three Dimensional Printing and CNC Machining

We are on the cusp of 4th industrial revolution, where physical and digital technologies will radically alter how companies produce, conceive, designs, distribute and repair nearly everything. In the field of 3D printing and CNC machining, technological innovations aimed at reducing the maintenance

Project Title

Three Dimensional Printing and CNC Machining

Project Area of Specialization

3D/4D Printing

Project Summary

We are on the cusp of 4th industrial revolution, where physical and digital technologies will radically alter how companies produce, conceive, designs, distribute and repair nearly everything. In the field of 3D printing and CNC machining, technological innovations aimed at reducing the maintenance cost, while delivering twice the performance.3D Printers and CNC machines are a new generation of machines that can produce, create and design different objects in different materials.

When designs are still fluid and product specification are in flux, two common choices are 3D printing and CNC(Computer Numerical Control) milling. Through functional prototypes, both 3D printing and CNC can meet the needs for early concept models without the delays imposed by mold, tool or die making. Both technologies can produce the low part quantities needed for product development at a reasonable cost.

In this project, we are making 3D-Printer machine by using an additive process, where we are willing to make 3-Dimensional objects by laying down successive layers of material to form our final objects. The 3D printing technology is employed for both prototyping and distributed manufacturing with applications in industrial design, automotive, engineering, dental industries ,jewelry, architecture and lots of other fields. By modifying this 3D printer, we would be capable to make a CNC machine to manufacture the design profile.

Project Objectives

To Print complex and Intricate parts of object- As we know technology is taking over and things are getting revolutionized in every aspect, people tend towards those solutions which enables them to make their desired products with least cost. The way we manufacture things, from tools and toys, to clothes, and even body parts, is changing with 3D printing. We aim to make a 3D printer that enables us to produce complex shapes using less material than traditional manufacturing methods.

Designing of CNC Machine- Our aim is to make a machine that can perform both tasks of creating a shape and designing a profile or a letter on it. Once  we create a shape or a part of an object, our next goal is to make a CNC machine using that old setup.

Improve quality of the production- Our goal is to enhance lean manufacturing by significantly reducing the cycle time of processes and increasing flexibility, thereby improving the overall quality of the product. We will fabricate parts with a level of precision that is nearly impossible to achieve with conventional hand-operated equipment.

Project Implementation Method

The first step is to design a 3D printing model using computer software. We need to design a 3D object models using special type of computer software known as  Fusion360. We will be using numerically controlled programming language made up of a series of commands called G-code. To convert 3D object model to G-code, we will be using a computer software, known as Cura. Then we will upload Hex file to Arduino mega by using Xloader software.

The next step is to build and print the object. For creating three dimensional objects, there is a variety of methods and technologies, we will be using Fused Deposition Modeling(FDM). FDM uses a plastic filament or metal wire as input material to an extrusion nozzle. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by CAM.  The material hardens immediately after extrusion from the nozzle. By using this method, 3D printer will build the bottom layer first, after which it will build the next-highest layer. The FDM 3D printing system move along three different orthogonal axis: X-axis, Y-axis and Z-axis. The X-axis corresponds to 3D printer’s horizontal movement(from left to right). The Y-axis is responsible for back and forth movement. While Z-axis corresponds to 3D printer’s vertical movement. These coordinates determine the position of hot end nozzle and along with this, we will be using a Laser(CNC) to design a letter or a profile to  that printed object.

Benefits of the Project

Advantages of 3D Printing

3D Printed Kidney-
The Millennium saw the first 3D printed kidney in 2000. Researchers are very quickly experimenting with exponential growth of transplant organs.

IN MEDICAL FIELD-
In 2008, 3D printing, a medical application, had an even greater media presence: the first prothetic  limb  was printed.

In 2016, the laboratory of Daniel Kelly revealed the possibility of 3D bone printing. Propelling the spotlight on 3D printing and bringing the word to millions across the globe.

"Bioprinting" in the medical sector is becoming the main focus. . It could create human tissue for burn victims. It could also create human organs.

Automotive sector
In 2010, the first 3D printed vehicle was the Urbee. Using a massive 3D printer, the body was entirely 3D printed. 3D printed vehicle is shown in the Fig 2.5. From the integration of 3D printed technology for the tooling process to 3D printed car parts additive manufacturing appears to be helpful in many levels and helping to go through the new challenges.

Construction Sector
Printing concrete in 3D is a real thing now. French start-up XtreeE, which is revolutionizing the building industry by 3D printing concrete. As shown in the Fig 2.6 below. Families are beginning to move into houses printed in 3D. The first family moved to 3D printed houses in 2018.

Projects that are quicker to build, cheaper and reduce material waste.

CNC Machining Advantages

The advantages of CNC machines in comparison to conventional machining methods are numerous; these machines use higher levels of automation and reduce possible errors while increasing productivity and cost-effectiveness across the board. 

Productivity

Because you can programme a CNC mill or other machine to perform a complex series of actions, you can often step away while the machine gets to work. This can include out-of-hours automated machining in certain set-ups, hugely increasing your productivity and rate of output.

Consistency

Because the use of a CNC almost eliminates human error, CNC machines are highly consistent and accurate in the work they produce, providing clients with uniform and faultless products. This is what makes CNC machining so crucial for areas where quality is critical, as the level of reliability and quality in the work produced is much higher.

Cost Effectiveness

CNC machines more than make up for their initial costs with a high rate of output and lower number of mistakes in resulting components. Operators also require less training to operate a CNC machine and can learn how to use the machine in a virtual environment, eliminating the need for training workpieces. As these machines become more popular and widespread, their cost will continue to drop.

Safety

Any hazardous safety issues, such as a jam or other machining error, is only detrimental to the machine and not a safety issue for the operator, unlike conventional open guard machining.

Technical Details of Final Deliverable

Our focus is on rapid prototyping to support the product development cycle. .The first step is to design a 3D printing model using computer software. We need to design a 3D object models using special type of computer software known as  Fusion360. We will be using numerically controlled programming language made up of a series of commands called G-code. To convert 3D object model to G-code, we will be using a computer software, known as Cura. Then we will upload Hex file to Arduino mega by using Xloader software.

The next step is to build and print the object. For creating three dimensional objects, there is a variety of methods and technologies, we will be using Fused Deposition Modeling(FDM). FDM uses a plastic filament or metal wire as input material to an extrusion nozzle. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by CAM.  The material hardens immediately after extrusion from the nozzle. By using this method, 3D printer will build the bottom layer first, after which it will build the next-highest layer. The FDM 3D printing system move along three different orthogonal axis: X-axis, Y-axis and Z-axis. The X-axis corresponds to 3D printer’s horizontal movement(from left to right). The Y-axis is responsible for back and forth movement. While Z-axis corresponds to 3D printer’s vertical movement. These coordinates determine the position of hot end nozzle and along with this, we will be using a Laser(CNC) to design a letter or a profile to that printed object.

By this method , we print a plastic dice and by using Laser(CNC), We modify this object and we will design dots from 1 to 6 at different positions.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Manufacturing

Other Industries

Others

Core Technology

3D/4D Printing

Other Technologies

Others

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and Production, Partnerships to achieve the Goal

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com