OPTIMIZATION OF 3D PRINTING PROCESS

FOR A STARTUP COMPANY

A PROJECT PROPOSAL
SUBMITTED TO

INDIAN INSTITUTION OF INDUSTRIAL

ENGINEERING

To be carried out at:

(THE VISION AS, STAVANGER, NORWAY)

By

HEMENDRASING BALRAM SHARNAGAT (S-44716)

 TABLE OF CONTENT

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ABBREVIATIONS AND NOTATIONS v

CHAPTER 1 PREAMBLE 1
1.1 INTRODUCTION 1
1.2 PROBLEM ON HAND 1
1.3 IMPORTANCE OF THE PROBLEM 1
1.4 AIM OF THE PROJECT 2
1.5 SCOPE AND OBJECTIVE OF THE PROJECT 2

CHAPTER 2 DETAILS OF THE ORGANIZATION 3

1.1 INTRODUCTION 3
2.2 THE ORGANIZATION 3
2.3 PRODUCTION FACILITIES AND PROCESSES 3
2.3.1 Facilities 3
2.3.2 Processes 4
2.3.3 Services 5
2.3.3 Clients 5
2.5 OTHER RELEVANT INFORMATION 5
2.6 CONCLUSION 5
CHAPTER 3 THE PROBLEM ON HAND 6
3.1 INTRODUCTION 6
3.2 DETAILS OF THE PROBLEM 6
3.2.1 Problems Faced During the Development of Prototypes by 3D Printing 6
3.2.3 Criticality of the Problem 7
3.3 CONCLUSION 7

ii
CHAPTER 4 RELEVANT LITERATURE REVIEW 8
4.1 INTRODUCTION 8
4.2 3D PRINTING TECHNOLOGY, APPLICATION AND SELECTION 8

4.3 OPTIMIZATION OF ADDITIVE MANUFACTURING PROCESSES

FOCUSED ON 3D PRINTING 8

4.4. ADVANCES IN 3D PRINTING & ADDITIVE MANUFACTURING

TECHNOLOGIES 9

4.5. MANUFACTURING PARTS OPTIMIZATION IN THE THREE DIMENTIONAL

PRINTING PROCESS BY THE TAGUCHI METHOD 9
4.6 3D PRINTING CASE STUDIES 10
4.7 CONCLUSION 11

CHAPTER 5 DATA COLLECTION APPROACH 12

5.1 THE TYPE OF DATA NEEDED AND SOURCES 12
5.2 METHODS OF THE DATA COLLECTION 12
5.3 CONCLUSION 12

CHAPTER 6 ANALYSIS OF DATA 13

6.1 INTRODUCTION 13
6.2 CHOICE OF TECHNIQUES 13
6.3 RELEVANT ANALYSIS METHODS 14
6.3.1 Brain Storming and Interviews 14
6.3.2 Cause and Effect Diagram 14
6.3.3 Flowchart 15
6.3.4 Before and After comparison with original product 15

6.4 PROBLEMS ASSOCIATED WITH TAKING CORRECT DIMENSIONS OF

BROKEN PARTS 16
6.4.1 Challenge 16
6.4.2 Example 16
6.4.3 Lessons Learnt 16
6.4.4 Proposed Solutions 16

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 6.5 PROBLEMS ASSOCIATED WITH COMPLICATED DESIGN ARISING DUE
TO CURVES AND BENDS 16
6.5.1 Challenge 16
6.5.2 Example 17
6.5.3 Lessons Learnt 17
6.5.4 Proposed Solutions 17
6.6 PROBLEMS ASSICIATED WITH DEVELOPMENT OF A NEW PRODUCT 17
6.6.1 Challenge 17
6.6.2 Example 17
6.6.3 Lessons Learnt 17
6.6.4 Proposed Solutions 18

6.7 PROBLEMS ASSOCIATED WITH THE STRENGTH AND AESTHETICAL

LOOKS OF A NEW PRODUCT 18
6.7.1 Challenge 18
6.7.2 Example 18
6.7.3 Lessons Learnt 18
6.7.4 Proposed Solutions 18
6.8 CONCLUSION 18
CHAPTER 7 RECOMMENDATIONS TO THE COMPANY 20
7.1 BRIEF DESCRIPTION OF RECOMMENDATIONS 20

REFERENCES 21

iv
 ABBREVIATIONS AND NOTATIONS

3D – 3 Dimensional (x, y, z)
CAD – Computer Aided Design
AM – Additive Manufacturing

v
 CHAPTER 1
PREAMBLE

1.1 INTRODUCTION

3D printing techniques, also known as additive manufacturing techniques, are maturing

and increasingly being used as an alternative means for manufacturing niche product. “The
Vision AS” is Stavanger, Norway based Start-up Company that utilises these new
manufacturing techniques to manufacture custom designed products. The company’s goal
is to help other companies achieve their aims by providing them with specialised prototype
models. It aims to provide cost efficient service by optimising their manufacturing work
flow and utilizing the state-of-the-art 3D manufacturing techniques.

In this project work we shall study the manufacturing process of “The Vision AS”, identify
the technical challenges faced by them and recommend steps to optimise their process so
as to make their manufacturing process more effective and cost efficient.

1.2 PROBLEM ON HAND

A traditional manufacturing industry utilises various reductive methods such as milling,

lathing and casting to remove material to create parts or products. These methods are
usually not suitable for producing samples and prototypes because these processes often
work well for large scale production and may prove expensive for producing a limited
number of samples. In this report the problems faced by clients who approach The Vision
with unique problems shall be discussed as examples.

1.3 IMPORTANCE OF THE PROBLEM

Due to the high demand from customers, companies are striving hard to find ways to
incorporate the technology into their product development and manufacturing operations.
This gives enormous challenges to the organisations to identify technical problems and
other related important issues like reduction in lead time, and decrease in costs, while
designing the prototype product.

1
1.4 AIM OF THE PROJECT

Aim of the project is to identify problems and recommend solutions to improve the work
processes of a company involved in manufacturing prototype product by 3D printing.
The main goal has been divided into two sub-goals:

Understanding the current process; and

Development of an improved CAD design and 3D printing processes.

1.5 SCOPE AND OBJECTIVE OF THE PROJECT

The scope and objective of this project is:

To study in detail the present method of manufacturing using a 3D printing processes.

To identify common challenges faced during the 3d printing process.
To suggest possible solutions or alternative methods to overcome these challenges.
To demonstrate the viability of these recommendations in improving the manufacturing
process resulting in cost savings.

2
 CHAPTER 2
DETAILS OF THE ORGANIZATION

1.1 INTRODUCTION

This chapter shall describe in detail about the organization where the project will be
executed. The Name of the Organization is “The Vision AS” located in Stavanger,
Norway. Organization logo is shown in the fig.2.1.

Fig. 2.1 Organization logo

2.2 THE ORGANIZATION

“The Vision AS” is an upcoming small start-up company established in 2016. The
company has ambition to grow, expand and become technological hub in Norway for
manufacturing 3D printed prototype products for clients from different industries.

The main goal of the company is to attract new entrepreneurs and existing small scale
customers who are looking to develop their product with the help of 3D printing in less
time and at less manufacturing cost. The Vision uses broad expertise of skilled engineers,
architect developers etc. to provide services and deliver good quality product to customers
in the areas of animation, CAD and 3D printing.

2.3 PRODUCTION FACILITIES AND PROCESSES

2.3.1 FACILITIES

The company has 3D CAD design facilities and it is important part of 3D manufacturing
and design and development of prototype products. Currently company uses the following
CAD softwares:

- Autodesk Inventor
- Autodesk AutoCAD

3
- Micro station
- Solid Works
The Company has different types of 3D printing machines and currently uses the following
three machines for 3D manufacturing of prototype products:

- ProJet 660 PRO

- ProJet MJP 2500 Plus and
- Formlabs Form2

2.3.2 PRPCESSES

The process of creating 3D design can be divided into following phases,

- The procedure includes rough sketch, drawing a base model using 2D drawings, taking
oral ideas that company has to study and understand given input to development of the
task.
- Drawing layout, animation and modelling the object using 3D modelling software’s,
scanners which describes the final output of the completed computer graphics
- Converting 3D model to final product by 3D printing

Fig 2.3.2 Printing process phases

Customer comes with their basic idea and concept about making products for their purpose
and those thoughts and inputs are studied by internal responsible team and executed as per
customers demand. Figure 2.3.2 shows that printing process goes through the combination
of the above phases and a few other sub-phases, this completes the process of a 3D printing
production. There are enough softwares in the market to create 3D model in the software
that can range from low cost to high cost. Slicing is dividing the model into different parts
by making horizontal layers that needs to be done with slicing software. In some cases
slicing can be done in the 3D modelling software itself. After the completion of the final
step in which slicing is done, the model is ready to be printed layer by layer.

4
2.3.3 SERVICES

“The Vision AS” offers services of design and construction, 3D modelling, visualisation,
3D scanning, printing of prototypes product,. The organization carries out set of activities
from start to end to create value for its customers. The organisation also guarantees best
price in market, good quality product and flexibility in model design. The organisation
offers need of any assistance for creating any of these models with help of our skilled
team. The organisation specialising in CAD design and development of new ideas and
improving existing products. The services provide in office as well as on site as per
demand from customers.

2.3.3 CLIENTS

The company covers wide range of clients from small to large-scale industry with scope of
work based on 3D printing of prototype products. Company also aim to interact with
potential customers through presentation for companies, large institutions or individual
clients. At present company is looking to engage in the field of architects, landscape
architects, local councils, health services, construction industry, offshore and marine
modification suppliers and subsea equipment suppliers.

2.5 OTHER RELEVANT INFORMATION

All industry safety and environment norms are followed by the company and by all the
employees as per regulation of Norway’s working law and European working environment
law.

2.6 CONCLUSION

In this chapter the detailed information about the organization The Vision AS” shall be
discussed. “The chapter shall also introduce company’s involvement in additive
manufacturing to create new conceptual prototype model from start to end.

5
 CHAPTER 3
THE PROBLEM ON HAND

3.1 INTRODUCTION

In this chapter we will highlight the challenges that will come across while designing the
prototype by the company from start to end. During the research, the problems commonly
faced by the company shall be studied in detail and the causes and effects systematically
catalogued. The proper identification of challenges faced shall be used as a guide to
develop guidelines that may contribute in optimizing 3D printing process for
manufacturing prototype products for customers.

3.2 DETAILS OF THE PROBLEM

3.2.1 PROBLEMS FACED DURING THE DEVELOPMENT OF PROTOTYPES BY

3D PRINTING

To go into the details of the problem, it is important to understand the types of products
desired by the clients and the challenges faced in manufacturing them. Two of the major
causes for disruptions are:

Since, the company is a new start-up company and still in developmental phase, all the
procedures, workflows and guidelines have not been standardised.
Individual customers have unique requirements; hence, it is difficult to develop
standard solutions.

In addition to developing standards for the work optimization, development process shall
also be carried out for new and existing product processes.
Following is the list of challenges faced during the development and optimization stages:

Missing base line for development of concept, idea and plan for CAD design
Insufficient/ improper inputs from customer for expected outputs
Complexity of the physical object to perform measurements
Missing standards for preferred orientation of printing
Inadequate tools to perform physical measurements

6
 Quality and process check list missing for the design and printing process
Since each product is unique, new product developed strategy is needed for each
product
Geometry, shapes and tolerances cross check in 3D CAD model
High focus on cost optimization
High level of co-ordination required with customer and suppliers

3.2.3 CRITICALITY OF THE PROBLEM

Any point affecting customer satisfaction should be considered as crucial, and it should be
resolved as early as possible. Customer satisfaction is an important element for making
profit for the organisation. The non-functioning product causes the major impact on
manufacturing process and cost. Also it effects final product delivery time and man-
machine hours which are consumed during this process. Over all it impacts on the whole
process of manufacturing and cost saving.

3.3 CONCLUSION

This chapter shall discuss the challenges faced while developing prototype parts by 3d
printing. Thus work needs to be carried out to find the precautions that need to be taken
while designing prototype and alternative solutions to these problems. The guidelines
developed that be used for improving the quality of the product productivity, reliability,
robustness, performance, and maintainability.

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 CHAPTER 4
RELEVANT LITERATURE REVIEW

4.1 INTRODUCTION

In this chapter we shall discuss, about the appropriate solutions and methods to find out the
best suggestions to optimizing 3D printing process to manufacture prototype products. For
that we have taken the references and case study of relevant field study from literature
review which explained in books, article and journals. Initial literature survey has shown
that the following references may prove helpful:

4.2 3D PRINTING TECHNOLOGY, APPLICATION AND SELECTION

Author: Rafiq Noorani

Summary: This book describes the 3D printing process and its application. 3D printing is a
fast and more cost-effective method for building prototypes products using three-
dimensional computer-aided design drawings. The book provides a fundamental overview
of the general products design and manufacturing process and presents the technology and
application for designing and fabricating parts that makes learning and understanding easy.
In this research we have to analyse and give additional arguments for advantages and
reason of more effective 3D printing process for a start-up company
Learnt from this Book:

- Knowing about additive manufacturing, 3D printing, and rapid prototyping.

- Understanding the step-by-step process to show how to design a prototype part
- Hands-on approach of designing a 3D printer and its applications.

4.3 OPTIMIZATION OF ADDITIVE MANUFACTURING PROCESSES

FOCUSED ON 3D PRINTING

Author: Anisor Nedelcu and Razvan Udroiu

Summary: In this book authors have explained methods of optimisation of additive
manufacturing process and presented explanations for surface roughness. They have also
proposed optimisation approach for three additive manufacturing applications. First, the
8
orientation of one part on a build tray and build time identification test, minimum support
structure and best quality surface. Second application is focused on fitted testing of parts
obtained by 3D printing and taken into its applications and third experimental investigation
on surface roughness of rapid prototyping products produced by polyjet technology used
and checked by surtronic 25 for surface roughness.
Learnt from this Book:

- Basic information and selection of optimisation for additive manufacturing process

- Understand the three area where focused on 3D printing parts orientation, fitting and
printing layer selection for surface roughness.
- Selection of machine based on its capacity and result.

4.4. ADVANCES IN 3D PRINTING & ADDITIVE MANUFACTURING

TECHNOLOGIES

Author: David Ian Wimpenny

Summary: This book has explained the advanced technologies for 3D printing and additive
manufacturing and how these technologies have changed the trend of direct, digital
technologies for rapid production of models, prototypes and patterns. Because of its wide
applications, 3D printing and additive manufacturing technology has become a powerful
new industrial revolution in the field of manufacturing. The evolution of 3D printing and
additive manufacturing technologies has changed design, engineering and manufacturing
processes across industries such as consumer products, aerospace, medical devices and
automotives.
Learnt from this Book:

- Understanding the printing layer system and resolution of layer

- AM use for unmatched and flexibility with complex products manufacturing.
- Material composition and lead time.
- Multi objective working with additive manufacturing process.

4.5. MANUFACTURING PARTS OPTIMIZATION IN THE THREE

DIMENTIONAL PRINTING PROCESS BY THE TAGUCHI METHOD
Author: Chung-kuo Kung Ch'eng Hsuch K'an

9
Summary: This journal paper mentioned the functional requirements of three-dimensional
printing systems that are speed, accuracy and the strength of the part. These functional
indices are significantly affected by the properties of the adopted materials and the
manufacturing process parameters of the rapid prototyping machine. The four most
important process parameters were systematically investigated in this journal study. The
authors have used the ANOVA analysis techniques of the Taguchi method and adjusting
the shrinkage setup values and dimensional accuracy error.
Learnt from this Journal Paper:

- Understanding the speed of 3D printer system

- Knowing the strength and functional properties of material
- Knowing about process parameters for accuracy

4.6 3D PRINTING CASE STUDIES

Author: Ken Nyren

Summary: In this article author from Axon LLC, has explained the problem thet they were
facing in manufacturing machinery that could be used to apply sleeve labels that shrink to
fit a product’s surface when heat is applied . The author has also discussed how 3D
printing techniques helped him solve this challenge.
Challenge: One of the company’s challenges is that almost every machine it builds
requires custom tooling to shape the label to fit over the container. Hundreds of fixtures,
called “pucks,” are also needed for many types of containers to hold them stable while the
label is applied. Increasingly, packages are being manufactured in complex shapes that
require tooling and pucks with intricate geometries that, if produced with less-than-
exacting precision, could jam the machine.
In the past, the company produced prototype tooling, production tooling and pucks by
machining them from plastic. Production typically took one week for tooling, two weeks
for a prototype puck and three weeks for all the pucks needed for a machine. Frequently,
prototyping revealed needed changes and the process would start again. In a few
particularly challenging applications, the tooling was not ready within the company’s
typical eight-week machine build cycle, which delayed shipment and delivery to the
customer end.
10
Solutions: The Company used the 3D printing of prototypes product to produce tooling and
pucks. Company selected a mid-size PolyJet 3D Printer because of the technology’s fast
print speed and optimize the process of printing speed, accuracy, temperature of nozzle and
selection of material within plastic. They have made proper work flow to go through with
step by step design process and cross check and verification of tooling and pucks.
With the 3D printer, Axon now prints tooling for a shrink or stretch sleeve in one day.
Engineers try out the printed part on the machine and if it doesn’t work, they can make a
change and print out the new tool the same day. The cost of printing the four pieces that
make up the tooling is only $720, compared to $2,400 for machining the parts. “A major
advantage of 3D printing is that to get immediate feedback,” Nyren said. “This maintains
the continuity of the design process and helps us create better tooling designs.”
(Referenced-11).
This case study applicable in our case, to implement and optimize the process of 3D
printing techniques to make prototype products for complex design and verities products.

4.7 CONCLUSION

From literature review, a lot of information related to optimize the 3D printing process in
various areas from start to end with product development and manufacturing can be learnt.

In this chapter we shall carry out detailed literature survey of books, journal papers and
case studies. This literature shall be used to get theoretical background behind the related
project work.

11
 CHAPTER 5
DATA COLLECTION APPROACH

5.1 THE TYPE OF DATA NEEDED AND SOURCES

In 3D printing process, data can be divided into two types:

Primary data that is the physical information about the object or product, like
dimensions such as height, width and length, area and volume, etc.
Secondary data is more subjective about the object or product, information like
appearance, attractiveness, surface finishing, colour, etc.

For primary data collection of all the products listed in this report, either the broken
product for restoration have been physically available or base frame for mounting the new
product have been available.

The secondary data shall be provided by client and additionally secondary information can
also be located from relevant literature and journals.

5.2 METHODS OF THE DATA COLLECTION

A formal data collection process is necessary as it ensures that data gathered are both
defined and accurate and that subsequent decisions based on arguments embodied in the
findings are valid. The process provides both a baseline from which to measure and in
certain cases a target on what to improve.
The data shall be collected and used with due permission in company. The collection
methods shall be used such as observations, measurements, stored data inventory, senior
colleagues and team members and the data will be collected by electronically or by means
of paper.

5.3 CONCLUSION

This chapter shall explain in detail about the type of data needed for this project, their
source, methods and processing of collection in detail.

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 CHAPTER 6
ANALYSIS OF DATA

6.1 INTRODUCTION

In this chapter the data collected and its analysis shall be discussed. Based on the analysis
of the data major findings shall be reported and discussed. The chapter shall also discuss
the suggestions for possible improvement in 3D prototype products manufacturing process.

6.2 CHOICE OF TECHNIQUES

This section, based on the literature review, shall discuss the choice of techniques that are
suitable for the objectives and characteristics of the aim and scope.
The techniques that are suitable for the task at hand can be characterised in broadly the
following groups:
a) Descriptive – the main purpose is to find out and describe how something is
working or is executed.
b) Exploratory – the main purpose is to gain a deeper understanding about how
something is working or is executed.
c) Explanatory – the main purpose is to find cause and effect relationship and
explanations for how things are working or are executed.
d) Improving/normative – the main purpose is to find a solution to an identified
problem.

Depending upon the purpose, a study can consist of a number of sub-studies. Thus in this
study the various techniques that shall be adopted are:

a) Descriptive – The process adopted by the company “The Vision” for

manufacturing the prototype or replacement parts shall be discussed.
b) Exploratory – Individual steps of manufacturing shall be discussed in detail.
c) Explanatory – The challenges faced at various steps of manufacturing shall be
discussed. Root cause analysis shall be carried out to identify causes of failures at
various steps.

13
 d) Improving/normative – Based on the study carried out practical solutions shall be
proposed to improve upon the existing process so as to save time and resources and
reduce chances of failures.

6.3 RELEVANT ANALYSIS METHODS

In order to carry out the above mentioned study techniques, various productivity
improvement techniques for the analysis of the working process and guidelines shall be
adopted. These include:

6.3.1 BRAIN STORMING AND INTERVIEWS

Brainstorming is useful because it can help a group of people utilize its collective
brainpower to generate many ideas in a short period of time. It stimulates creativity and
promotes involvement and participation.

This analysis method will be applicable on the basis of problem in hand; a team need to
figure out the best solution and method to execute well and details will be explained in
project report.

For this project, experienced members of technical staff of the company shall be
interviewed and asked for their opinion regarding reasons for failure, best practices, etc.

6.3.2 CAUSE AND EFFECT DIAGRAM

A common use of the cause and effect diagrams is product design and quality defect
prevention to identify potential factors causing an overall effect. Each cause or reason for
imperfection is a source of variation. Causes are usually grouped into major categories to
identify these sources of variation.

The categories typically include People, Methods, Machines, Materials, Measurements and
Environment. This diagram allows the team to systematically analyse cause & affect
relationships and details will be explained in project report.

14
In this project, a systematic study shall be carried out to identify the causes of individual
failures.

6.3.3 FLOWCHART

A flowchart is a formalized graphic representation of a logic sequence, work or

manufacturing process, organization chart, or similar formalized structure. The purpose of
a flow chart is to provide people with a common language or reference point when dealing
with a project or process. Flowcharts use simple geometric symbols and arrows to define
relationships.

In this project, work shall be done to identify and various processes and to make relevant
work flow diagrams.

6.3.4 BEFORE AND AFTER COMPARISON WITH ORIGINAL PRODUCT

In this section the comparison will be made between the existing work process and the
proposed work process. The comparison pictures will be shows before and after product
result and details will be explained in project report.

15
6.4 PROBLEMS ASSOCIATED WITH TAKING CORRECT DIMENSIONS OF
BROKEN PARTS

6.4.1 CHALLENGE

3D printing is a good methodology to make small parts that have broken and need to be
replaced in case the replacement parts are not available in the market. In such situation
taking correct measurements of the broken part and then preparing accurate CAD drawing
and finally making the replacement part become a challenge. Often after the production of
the part, the part does not align with the existing equipment. This is especially true if the
replacement part is a moving part that has low tolerances.

6.4.2 EXAMPLE

The company was asked by a client to make a small replacement part for a movie
projector. Due to the small size of the part, taking accurate dimensions and preparing CAD
model was found to be difficult.

6.4.3 LESSONS LEARNT

In this section the lessons learnt for taking accurate dimensions shall be discussed.

6.4.4 PROPOSED SOLUTIONS

Based on the lessons learnt possible solutions shall be proposed and the applicability of
these solutions for improvement of the manufacturing process shall be discussed.

6.5 PROBLEMS ASSOCIATED WITH COMPLICATED DESIGN ARISING

DUE TO CURVES AND BENDS

6.5.1 Challenge

When a broken replacement part needs to be remade using 3D printing, problems arise in
developing a 3D CAD model of the broken part. The problems are more in case the part
has a number of curves and bends. This problem gets aggravated if the tolerances required
are very small.

16
6.5.2 Example

The company was asked by a client to make a replacement part for a shower cabinet’s
water drain system. Due to the presence of curves, uneven bends, and difference in
thickness at bottom and top; taking accurate dimensions with present measuring tools was
found to be difficult for preparing CAD model.

6.5.3 Lessons Learnt

In this section the lessons learnt for taking accurate dimensions and 2D drafting of part and
conversion in 3D CAD model should be discussed.

6.5.4 Proposed Solutions

Based on the lessons learnt possible solutions shall be proposed and the applicability of
these solutions for improvement of the manufacturing process shall be discussed.

6.6 PROBLEMS ASSICIATED WITH DEVELOPMENT OF A NEW PRODUCT

6.6.1 Challenge

In the development of a new product where there is no known product to study there are
possibilities of making design and manufacturing mistakes. In this section the checks
required to reduce the possibilities of these mistakes shall be discussed.

6.6.2 Example

A client had developed a concept of foldable ski and to demonstrate the idea he needed a
prototype part it. Due to new development of the concept, making of a prototype ski
bracket for folding system was found to be challenging.

6.6.3 Lessons Learnt

In this section the lessons learnt in developing new parts without any prior sample to work
with shall be discussed.

17
6.6.4 Proposed Solutions

Based on the lessons learnt possible solutions shall be proposed and the applicability of
these solutions for improvement of the manufacturing process shall be discussed.

6.7 PROBLEMS ASSOCIATED WITH THE STRENGTH AND AESTHETICAL

LOOKS OF A NEW PRODUCT

6.7.1 Challenge

In the development of a prototype product, often the two major requirements are the
strength and aesthetical looks of the product. 3D printed product can often be either weak
in structure or does not have an appealing finish. In this section the importance of proper
design and the cautions during the printing processes shall be discussed.

6.7.2 Example

A client developed an Autonomous Intelligent Vehicle’s base model called “Robot”. For
the purpose of demonstrating the concept, the client wanted the company to develop a
prototype of Robot’s upper body that could be installed on the existing model. Due to the
size, shape and aesthetical look, it became difficult and challenging for CAD modelling
and 3D printing. Details of the requirements shall be discussed in this section.

6.7.3 Lessons Learnt

In this section the lessons learnt for taking challenges to develop a new prototype model
while taking case of strength and aesthetical appeal of the product shall be discussed.

6.7.4 Proposed Solutions

Based on the lessons learnt possible solutions shall be proposed and the applicability of
these solutions for improvement of the 3D manufacturing process shall be discussed.

6.8 CONCLUSION

This chapter shall discuss in detail the work carried out to understand the processes
adopted by the company for manufacturing various client specific parts. In the next step
18
the problems faced by the company in designing and developing the products shall be
discussed. Finally, suggestions shall be made so as to avoid making the same mistakes in
future and for improving the process flow.

19
 CHAPTER 7
RECOMMENDATIONS TO THE COMPANY

7.1 BRIEF DESCRIPTION OF RECOMMENDATIONS

The true impact and benefit of a business improvement is not just finding the solution to a
specific problem, but expanding the application of the solution across a wider business
enterprise. These expansions are referred to as replication and standardization.

Based on the research work carried out in this project important recommendations shall be
made to the company.

20
 REFERENCES

1] Rafiq Noorani, 2017, 3D Printing Technology, Application and Selection, Professor of

Mechanical Engineering at Loyola Marymount University in Los Angeles, California, pp.
271.

2] Anisor Nedelcu and Razvan Udroiu, 2011, Optimization of Additive Manufacturing

Processes Focused on 3D Printing, Professor of Manufacturing Engineering Department at
Transilvania University of Brasov, Romania, pp. 1-25.

3] Jorge Cambaa, Manuel Conterob and Pedro Companyc, 2017, A survey on 3D CAD
model quality assurance and testing tools, Department of Mechanical Engineering and
Construction, Universiat Jaume and Gerald D. Hines College of Architecture and Design,
University of Houston, 4200 Elgin St, Houston, USA, Vol. 83, pp. 64-79.

4] Marlin Steel, 2015, 3D Printing vs Traditional Manufacturing, Article from Marlin

Steel, 2640 Merchant Drive Baltimore, MD, USA.

5] Zanni C. and Kobbelt L, 2016, Improved Surface Quality in 3D Printing by Optimizing

the Printing Direction, RWTH Aachen University Germany, Vol. 35, pp. 1-12

6] David Ian Wimpenny, 2017, Advances in 3D Printing & Additive Manufacturing

Technologies, Manufacturing Technology Centre (MTC), Coventry, UK.

7] Anand S. and Ratnadeep P., 2011, Optimal part orientation in Rapid Manufacturing
process for achieving geometric tolerances Journal of Manufacturing Systems, pp. 214-222

8] Brajlih T, Valentan B, Balic J and Drstvensek I, 2010, Speed and accuracy evaluation of
additive manufacturing machines Rapid Prototyping Journal, pp. 64-75

21
9] D. Dimitrov, W. van Wijck, K. Schreve, N. de Beer, 2006, Investigating the achievable
accuracy of three dimensional printing Rapid Prototyping Journal, pp. 42-52

10] T.-J. Hsu, W.-H. Lai, 2010, Manufacturing Parts Optimization in the Three-
Dimensional printing Process by The Taguchi Method, Journal of the Chinese Institute, pp.
121-130

11] Ken Nyren, 2017, Axon LLC, 3D printing saves Axon 90% on tooling cost and time,
Article from Stratasys.

Date: Place: Stavanger, Norway

Hemendrasing Balram Sharnagat Dr. Maneesh Singh

Student (44716) Project Guide

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