DML LAB :

Name : Sagar Gurav

Rollno : C224
Course : BTech Aiml .

Q.1 ] What is difference between welding, soldering

and brazing in joining process ?
ANS : Common features ,
Joining metal requires soldering, brazing, and welding.
And while each of these methods is different, they also
have a few things in common.

 Cleaning the metal pieces: Whichever process you

choose, you will not be completely successful
unless you start with clean material.
 Heating the material: All three methods require
adequate heat to create a strong joint.
 Proper safety equipment: Using eye protection,
safety gloves, protective clothes, and helmets is an
essential part of each of these methods.

1 ] Brazing :
  The brazing process combines heat, filler material,
and flux to join two or more metals. A flux solution
between the filler metal and base metal helps to
join them during heating. The melting point of the
filler metal is above 850°F, but it is always lower
than the melting temperature of the metals being
joined. The molten filler metal cools, providing a
strong join between the same or different types of
metals.
 Brazing works well for thin metals such as
aluminum, where higher temperatures can damage
them. Because of its flexibility and the high
integrity to which joints can be created, brazing is
used in a wide variety of industries. It is reliable in
various applications, making it one of the most
popular joining methods.

 The Pros and Cons of Brazing

Pros Cons
Base metal does not Larger sections cannot be
melt joined
Neat joints without Joint not as strong as with
cleaning welding
Can join dissimilar Possible toxic elements in the
metals filler material
Economical way to fuse High temperature can damage
materials the joint
Joint color differs from base
Simple technique
metal

2 ] Soldering :
Solder is the filler metal melted at a relatively low
temperature (under 800°F) using a soldering iron. The
soldering process joins metal parts to form a
mechanical or electrical bond. The solder bonds to the
metal parts, creating a connection after the solder
solidifies.

Even though soldering is used for plumbing, sheet

metal fabrication, and automotive radiator repair, the
most common application of soldering is assembling
electrical components and wiring electrical contacts. As
with brazing, the joined parts are not melted and are
often a different material than the solder.

THE PROS AND CONS OF SOLDERING

Pros Cons
No need to melt the
Cannot fuse larger sections
base metal
Low-temperature
Low-strength joints
process
Thin-walled parts can be Unfit for high-temperature
joined applications
It may contain toxic
Low-cost method
components
Easy to learn

3 ] Welding :
Unlike in brazing and soldering, a high temperature is
used in welding to heat the filler material and the
edges of the base metal, establishing a strong bond
between the metals. Temperatures over 850°F create a
weld pool of molten metal that cools to form a much
stronger joint than either brazing or soldering. Shielding
gas is sometimes used in the welding process to
protect the melted and filler metals from becoming
contaminated or oxidized.

Welding is employed in various industries, including

construction, automotive, aircraft, pipelines, tanks,
vessels, bridges, and railroads. And there are several
welding methods from which to choose: MIG, TIG, stick,
laser, gas, and underwater welding are just some of the
most common.

THE PROS AND CONS OF WELDING

Pros Cons
Works on a variety of Some danger from heat, light,
materials and radiation
Strong and secure
Can be expensive
joints
It can be done almost Typically not suitable for thin
anywhere metals
Large sections are
Base metal contortion
easily joined
Relatively economical
procedure

akshaymali0182@gmail.com
Brazing Soldering Welding
It produces the
Joints are Strongest joints
weakest joint of
stronger than capable of bearing
the three.
soldering but loads. The strength
Typically used for
weaker than of a welded joint
electrical
welding. It can often exceeds the
contacts, it cannot
be used to bear strength of the
bear much
some load. base metal.
weight.
Temperatures Temperatures of
Temperatures
can be as much up to 7,000°F
around 800°F
as 1,000°F possible
The workpiece is No heating The workpiece is
heated below its required on the heated to the
melting point workpiece melting point
The mechanical
The mechanical No change in properties of the
properties of the mechanical base metal may
joint may show a properties after change in the joint
negligible change joining. because of heating
and cooling.
The costs
involved and the The costs involved
It can require high
skills needed are and the skill
costs and high-
in between the requirement is
level skills.
two other very low.
methods
Often requires
heat treatment to
No heat
No heat treatment eliminate the
treatment
unwanted effects
of welding.
Because brazing Preheating the Since it is
is done at low workpiece before performed at a
temperatures, soldering is also high temperature,
preheating can good for making preheating the
 work is not
help to form a
quality joints. necessary for
solid joint
welding.
Q.2 ] What are the Application of additive
manufacturing components / products or were the
additively manufacturing products are used ?
Ans : 1. Aerospace :

Aerospace companies were some of the first to adopt additive

manufacturing. Some of the toughest industry performance
standards exist in this realm, requiring parts to hold up in harsh
conditions. Engineers designing and manufacturing for
commercial and military aerospace platforms need flight-worthy
components made from high-performance materials.

With ITAR registration and both ISO 9001 and AS9100

certifications, Stratasys Direct Manufacturing has had the
opportunity to see a range of innovative designs transform the
production of aerospace parts for major companies. Common
applications include environmental control systems (ECS)
ducting, custom cosmetic aircraft interior components, rocket
engines components, combustor liners, tooling for composites,
oil and fuel tanks and UAV components.

3D printing delivers complex, consolidated parts with high

strength. Less material and consolidated designs result in
overall weight reduction – one of the most important factors in
manufacturing for aerospace. The benefits of additive
manufacturing for major companies and organizations
continues to push forward the innovative designs and
applications for the world of flight.
2. Medical :

The rapidly innovating medical industry is utilizing additive

manufacturing solutions to deliver breakthroughs to doctors,
patients and research institutions. Medical manufacturers are
utilizing the wide range of high-strength and biocompatible 3D
printing materials, from rigid to flexible and opaque to
transparent, to customize designs like never before.

From functional prototypes and true-to-life anatomical models

to surgical grade components, additive manufacturing is
opening the door to unforeseen advancements for life-saving
devices. Some applications shaking up the medical industry are
orthopedic implant devices, dental devices, pre-surgery models
from CT scans, custom saw and drill guides, enclosures and
specialized instrumentation. Stratasys Direct Manufacturing
continues to expand its offering to support medical applications
such as anatomical models and custom surgical tools.

Material development is also key in this industry – the more

validation of biocompatible materials and the methods used to
produce parts could open the door for more customized
implants, life-saving devices and pre-surgical tools that
increase patient outcomes.
3. Transportation :

Life in the fast lane means endurance to tough environments

like extreme speeds and heat. The transportation industry
needs parts that stand up to harsh testing and are lightweight
enough to avoid unnecessary drag. With a wide array of
rugged, high temperature materials and additive manufacturing
technologies and the ability to build very complex geometries,
transportation companies are just scratching the surface of
what can be made additively manufactured for their vehicles.

We have helped automotive suppliers and companies develop

consolidated, lightweight components that lead to more efficient
vehicles. Some of the applications that have transformed the
industry include complex duct work that can’t be fabricated with
conventional manufacturing methods, resilient prototypes,
elastomeric models, grilles, custom interior features and large
paneling. The continuing advancements in 3D printing have
opened up new opportunities for end-use and mass
customization applications
4. Energy

Success in the energy sector hinges on the ability to quickly

develop tailored, mission-critical components that can
withstand extreme conditions. Additive manufacturing’s
advancements in producing efficient, on-demand, lightweight
components and environmentally friendly materials provide
answers for diverse requirements and field functions.

Some key applications that have emerged from the gas, oil and
energy industries include fluid/water flow analysis, flow meter
parts, mud motor models, pressure gauge pieces, and control-
valve components.

With the development of corrosion-resistant metal materials for

customized parts that may need to experience underwater or
other harsh environments, there’s no telling what major energy
companies may accomplish with additive manufacturing.
5. Consumer Products :

For designers, graphic artists and marketing teams, the time it

takes to form an idea and deliver it to the market is everything.
Part of that time is simulating the look and feel of the final
product during design reviews to prove ideas to key
stakeholders. Consumer product manufacturers have
embraced 3D printing to help develop iterations and quickly
adjust design.

3D printing is great for producing detailed consumer electronics

early in the product development life cycle with realistic
aesthetics and functionality. Sporting goods have benefited
from early iterations delivered quickly and with fine details.
Other successful applications include entertainment props and
costumes, lightweight models and sets, and finely detailed
architectural models.

As 3D printing technology advances in speed and build volume,

more consumer products may turn to additive manufacturing for
their large volume demands.
 Medical device manufacturers use 3D printing to develop high
variance products such as dental implants. Furthermore,
computer-aided designs can be made for a specific patient,
ensuring a more comfortable fit.
 In the automotive industry, additive manufacturing techniques
have gone beyond rapid prototyping and are now used to build
strong, lightweight car parts. As a result, high-end cars can get
lighter, stronger carbon fiber parts to improve performance.
 The aerospace and defense industry also uses additive
manufacturing for lightweight, strong parts. After all, planes and
shuttles must withstand the excessive forces experienced
during takeoff and flight, and the use of 3D printed, layered
composite parts are a great solution for this specific use.
 More common discrete manufacturers also use additive
manufacturing techniques for faster product development and
prototyping, reducing the time it takes to bring an item from
minimal viable product to full production.
As discussed throughout this post, additive manufacturing is
clearly a technology that provides significant benefits across
different use cases depending on a manufacturer’s specific
needs. Tulip works with a number of manufacturers that use
our frontline operations platform to help track and manage the
production of 3D printed items across print farms used by
Formlabs and Original Equipment Manufacturers like Stratasys.
By leveraging a platform like Tulip, manufacturers using 3D
printing technology can guide operators with digital workflows,
connect and visualize data generated by 3D printers, track
production statuses in real-time, and identify the sources of
quality issues to drive continuous improvement.

Dental
Dental labs and practices have used 3D printing technology for
decades to produce dental devices and models, and surgical
tools. Providers produce dental appliances to fit each patient –
customized. Traditional device production is a multi-step
process that is time-consuming and can be uncomfortable for
the patient if an oral mold is taken. 3D printers digitalize the
process, eliminating labor-intensive steps and accelerating
device turnaround. Using conventional methods, devices like
night guards or retainers take longer and need to be recreated
manually if the patient loses the device. With a 3D printing
solution, the device or multiple devices are directly printed in
less than an hour.
Today’s dental 3D printing solutions can create:
 Dental models
 Surgical guides
 Night guards / retainers
 Dental try-ins
 Crowns and bridges
 Dental casting
 Indirect bonding trays
 Gingival masks
 Denture bases

Medical
The range of durable materials and customization possibilities
make additive manufacturing advantageous for developing
medical devices including custom products. Medical facilities
can use 3D printers to bring device creation in-house, enabling
better patient experiences and rapid service.
Available additive manufacturing applications include:
 Custom medical insoles for patients with diabetic foot
disease, inflammatory arthritis, plantar fasciitis, and more.
  Lattice casts are more comfortable, more functional, and
are faster to produce than conventional plaster casts.

 Custom medical pillows can help maintain alignment of

a patient’s spine and provide optimal support of the head,
neck, or other areas with specific shape, firmness, and
height / thickness.

 Medical braces are custom developed to support patients

as they grow or develop, such as scoliosis braces, or to
heal after surgery or injury to the area.

Footwear
3D printers give footwear companies more control over product
designs and accelerate the prototype to the production cycle.
Traditional production of footwear, such as injection molding,
has tooling needs that require significant time and financial
investment. Once a manufacturer completes tooling, significant
design alterations are cost-prohibitive. If market feedback leads
to a product redesign, it can take months to create new molds
and require significant costs to the company.
With no tooling, companies leverage 3D printers to expand
design and production possibilities and enable agile
manufacturing. Instead of taking months to create new molds
for a product change, designers can quickly alter a product’s
CAD file and begin 3D printing the latest model. No tooling
requirements also enable 3D printing smart factories to offer
lower MOQs than traditional manufacturing facilities as a single
machine at a site can make many different products. Low
MOQs allow footwear companies to make small batches or
experimental variants to gauge market feedback. With this
information, companies can make more educated decisions on
which products to produce at high volume or better meet
smaller or niche market demand.
Aerospace
With the ability to easily scale production with 3D printers, a
cost-effective low-volume production is now an option for
companies. As demand increases, production volume can also
increase in-step. Companies can also employ on-
The aerospace industry has a long history of using 3D printing
technology to create complex or low-volume parts and custom
tools. 3D printing offers a rapid and efficient way to develop
uniquely-shaped components without investing in expensive
molds and other single-purpose tooling. Aerospace designers
can create small batches of parts cost-effectively and on
location, enabling more rapid feedback.
The design and production capabilities of additive
manufacturing give engineers more control over the physical
properties of their components. For instance, weight is one of
the essential elements of aircraft design. Reducing aircraft
weight makes fuel consumption more efficient. Engineers use
3D printing software to lower part weight through lattice designs
or. consolidate parts to simplify the assembly process.

Energy
As with aerospace, the energy sector uses 3D printers to create
uniquely-shaped parts quickly and cost-effectively. Energy
companies use 3D printers to produce turbines, liquid pumps,
and other amorphous components without the tooling costs
associated with other industrial processes. If parts start to
malfunction, 3D printing’s on-demand production capability
enables rapid replacement of components.
Notable 3D-printed energy parts include:
 Gas turbine nozzles
 SSD sleeves
 Sand control screens
  Nozzles for downhole cleanout tools
 Subsea chemical stick injection tools
 Sealing accessories
 Perforated pup joints
 Liner hanger spikes

Automotive
The versatility of additive manufacturing can help automotive
manufacturers simplify and streamline the part production
process. During the initial design phases, engineers use 3D
printers to create highly detailed models that explore different
layout ideas. Aesthetic and functional prototyping can aid
designers in accelerating final product design. Companies use
the on-demand production style of 3D printing to make the
application’s perfect amount of products.
Automotive manufacturers utilize 3D printers to produce:
 Engine manifolds
 Air conditioning vents
 Aesthetic bezels
 Gear shift knobs
 Braking components

Consumer Goods
The diverse consumer goods industry includes sports
equipment, cosmetics, and eyewear. Increasingly, companies
are using 3D printers to make it easier to bring products from
design to production and provide a higher level of customer
service delivering cost-effective, customized products. Additive
manufacturing technology enables consumer goods companies
to continuously improve designs in response to customer
feedback and better respond to market demand. The design
freedom of 3D printing enables companies to experiment with
innovative designs and create customized products that match
consumer needs.
Typical consumer goods applications include:
 Eyewear
 Bike saddles
 Mascara wands
 Golf clubs
 Helmets

Websites Url :
https://luxcreo.com/top-seven-industries-for-additive-
manufacturing-applications/
https://www.stratasys.co.in/stratasysdirect/resources/articles/
unstoppable-industries-using-additive-manufacturing/
#:~:text=Some%20key%20applications%20that%20have,%2C
%20and%20control%2Dvalve%20components.
3 ] What are the Steps involving in 3D printing ?
Ans :

Additive manufacturing, often referred to as 3D printing, is a computer-

controlled process for creating 3D objects.

As the name implies, objects are built up by ‘adding’ material — usually

a plastic, ceramic, or metal powder — to a build platform in thin layers,
which are hardened using a curing agent, heat, or a laser beam.

But how does additive manufacturing work?

After all, the actual build is only one part of a much larger process. In this
article, we’ll look at the entire additive manufacturing process from start
to finish.

If you’re new to it, it’s easy to assume that the additive manufacturing
process falls into just two parts: design and printing. But that’s just not
the case.

The additive manufacturing process is really much more complex and

can be broken down into four main steps:

Step 1: Using CAD Software to Design a Model

As you’d expect, Computer-Aided Design (CAD) plays a critical role in

additive manufacturing. It’s used to design and test 3D models that are
viable for real-world applications.

Some of the top CAD software products for professional use include:

AutoCAD — one of the first CAD suites to be released, all the way back
in 1982. AutoCAD is widely used across all industries for 3D design, and
known to be extremely versatile in expert hands.

Creo — a market leader in product design that includes a wide range of

design functionality and the ability to complete dimension calculations
during the modeling process.
SolidWorks — widely used for industrial object design. Solidworks
includes an extremely wide range of engineering tools and features.

Step 2: Pre-Processing

Pre-processing covers a range of steps that must be completed between

design and manufacturing. It covers two primary activities:

1) Simulation modeling

Simulation modeling is used to digitally test 3D designs before they are

manufactured. These tests are used to determine the real-world
structural integrity of an object — i.e., whether it is likely to fail, how it
might fail, and what forces it can withstand without failing.

Common simulation modeling techniques include Computational Fluid

Dynamics (CFD), Finite Element Analysis (FEA), and Non-Linear Stress
Analysis.
2) Preparing Files for 3D printing

Once a 3D design has been tested and signed off, it’s ready to be
prepared for printing. To do this, a hurdle must be
overcome: interoperability.

Interoperability is the ability of different computer systems to exchange

and make use of information. In the additive manufacturing process, the
problem is simple — manufacturing machines like 3D printers don’t
‘understand’ CAD files well enough to enable the manufacturing process.

To overcome this, a file must be converted into a set of instructions that

can be understood by additive manufacturing hardware. These
instructions are created using ‘slicer’ software such as Spatial’s CGM
Polyhedra which converts the 3D design into 2D layers or slices which
can then be used to calculate the tool path or G-Code needed to
manufacture the object.

Step 3: Printing

Depending on the additive manufacturing technology being used, the

‘printing’ phase can look very different.

In a typical 3D printing process — like those seen in commercially

available 3D printers — print heads alternate a layer of powder material
with a layer of binding liquid. These layers are built up on top of each
other to form the final product. This process is more accurately called
‘binder jetting’.
However, other forms of additive manufacturing look quite different.

Stereolithography (SLA) uses powerful lasers in place of a liquid binder

to cure layers of photopolymer resin. During the build cycle, the building
platform is lowered into a pool of resin, into which the laser traces the
pattern of the layer being printed. Once each layer is cured, the build
platform is fractionally lowered into the resin pool.

On the other hand, in Fused Deposition Modeling (FDM), a thermoplastic

material is heated and applied to the build platform layer-by-layer. Once
a layer is dry, the next layer is applied on top of it.

Other common techniques include Selective Laser Sintering (SLS),

Metal Laser Sintering (DMLS), and Electron Beam Melting (EBM).
 Step 4: Post-processing

Post-processing is often the most expensive and time-consuming aspect

of additive manufacturing.

The steps vary depending on the type of additive manufacturing process

being used, but usually fall into three categories:

1. Build removal — Removing excess material from the object and build
platform.
2. Part separation — Removing the object from the build platform,
separating parts, and removing any support structures used to aid the
build process.
3. Debinding — Soaking objects in a solution to remove any excess
binding material.

Every Step is Critical

In manufacturing — and additive manufacturing in particular — cutting

corners is never an option. If you want real-world ready components,
every stage of the process must be completed with care and due
diligence.

If you can develop and maintain a consistent, effective process, you’ll be

in a great position to manufacture high-quality components time after
time.

Q What is a raft ?
A Raft is a horizontal latticework of filament that is located
underneath your part. Your 3D printed part will be printed
on top of this raft, instead of directly on the build platform
surface. Rafts are primarily used with ABS to help with
warping and bed adhesion, but they can also be used to
help stabilize models with small footprints, or to create a
strong foundation on which to build the upper layers of
your part.

Q What is a skirt?
skirt is an outline that surrounds your part but does not
touch the part. The skirt is extruded on the print bed before
starting to print your model. Skirts serve a useful purpose
because they help prime your extruder and establish a
smooth flow of filament.
Q What is a brim ?
A Brim is a special type of skirt that is actually
attached to the edges of your model. Typically,
the brim is printed with a increased number of
outlines to create a large ring around your
Q What is a support system ion 3d
printing
Unless your goals are limited to custom hockey pucks and
little gnome figures, support materials will play a critical role
in your 3D printing efforts. 3D printing support materials
enable you to create and print complex geometries, parts
with internal features, and parts that cannot be
manufactured by any other method. Without support, your
build material would deform before it hardened.