3D AND 4D PRINTING

3D PRINTING
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• Also known as Additive Manufacturing (AM).
• It is a process of creating three-dimensional objects by adding material layer upon layer.
• Materials used include plastics, metals, concrete and even biological materials.
• It is opposite of Subtractive Manufacturing where material is removed to create an object.
• Any complex shape can be formed by successive layering of material.
• Objects produced are rigid and retain their shape after printing.

Historical Background
• The first working 3D printer was developed in 1984.
• Invented by Charles W. Hull of 3D Systems Corporation.
• The technology was called Stereolithography Apparatus (SLA).

Basic Principle
• A 3D object is created by stacking multiple two-dimensional layers.
• Printing starts from the bottom and progresses layer by layer to the top.
• Final output is a complete three-dimensional structure.

Components of Additive Manufacturing
• Computer system
• 3D modelling software such as CAD (Computer Aided Design)
• 3D printer or machine equipment
• Layering material (plastic, metal, resin, etc.)

Process of 3D Printing
• A virtual 3D design of the object is created using CAD software or 3D scanners.
• The digital model is converted into a printable file.
• The model is sliced into hundreds or thousands of horizontal layers.
• The file is uploaded to the 3D printer.
• The printer reads each slice and prints the object layer by layer.
• The final product appears as a solid 3D object with minimal visible layering.

Applications of 3D Printing

Medical Sector
• Used by surgeons to print anatomical models for complex surgeries.
• Creation of customised bone grafts for accident and trauma patients.
• Development of surgical tools such as customised surgical bolts.
• Production of dental resins and materials to combat dental diseases.
• Manufacturing of highly porous pills containing high dosage in small size.
• Used in medical implants and prosthetics.

Manufacturing Sector
• Production of automobile and aircraft components.
• Used in manufacturing sports goods, toys and industrial parts.
• Enables mass customisation as designs can be modified digitally.
• Reduces dependency on traditional manufacturing processes.

Architecture and Construction
• Used for designing and building houses and construction components.
• Helps in creating customised luxury homes and temporary shelters.
• Enables restoration and reconstruction of heritage structures.
• Improves safety and strength through innovative structural designs.

Food Industry
• Enables automated and customised food production.
• Provides flexibility in food design and nutrition.
• Allows mass customisation of food products.

Environmental Benefits
• Produces minimal waste due to additive nature.
• Environment friendly compared to traditional manufacturing.
• Used in design visualisation, prototyping, metal casting and education.

Future Prospects of 3D Printing
• Space exploration: Ability to print tools and spare parts on-site.
• Bio-printing of tissues and organs is under research.
• Potential to reduce medical costs through customised healthcare solutions.

3D Printing in India
• Supported by government initiatives like Make in India, Digital India and Skill India.
• Growing adoption by manufacturing and industrial sectors.
• Foreign collaborations for setting up 3D printing facilities.
• PwC report indicates that around 27 percent of Indian industries are investing in AM technology.

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4D PRINTING
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• 4D printing is an advanced form of 3D printing.
• In 4D printing, objects can change shape or function over time.
• The fourth dimension refers to time.
• Transformation occurs due to external stimuli such as heat, water, light or air.
• Objects are printed using smart and programmable materials.

Concept of 4D Printing
• A 4D printed object is initially printed like a 3D object.
• After printing, it changes shape or behaviour when exposed to environmental conditions.
• Uses advanced materials like shape memory polymers and hydrogels.
• Non-living objects exhibit adaptive and responsive behaviour.

Technology Used
• Uses commercial 3D printers such as PolyJet printers.
• Smart materials respond to temperature, moisture or light.
• Materials possess thermomechanical properties enabling transformation.

Advantages of 4D Printing
• Objects larger than printer size can be printed in compressed form.
• Ability to self-assemble, shrink or unfold.
• Vast potential in material science and engineering.
• Multi-material shape memory polymers enhance functionality.
• Reduces need for complex assembly processes.

Applications of 4D Printing

Infrastructure and Utilities
• Pipes that change diameter based on water flow.
• Self-healing pipelines that repair cracks automatically.

Furniture and Consumer Goods
• Self-assembling furniture that changes shape when exposed to water or heat.
• Products that adapt to environmental conditions.

Space Applications
• Used to build self-assembling structures in space.
• Reduces cost, energy consumption and logistical challenges.
• Can be used to build shelters, bridges and repair structures autonomously.

Medical Applications
• Development of self-reconfiguring proteins.
• Biocompatible implants that adapt inside the human body.
• Use in minimally invasive medical procedures.

Consumer Products
• Clothing and footwear that adapt to temperature and humidity.
• Childcare products responsive to environmental conditions.
• Home appliances that adjust for comfort and efficiency.

Conclusion
• 3D printing focuses on creating static three-dimensional objects.
• 4D printing adds adaptability and time-based transformation.
• Both technologies are set to revolutionize manufacturing, healthcare, space and daily life.

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Subject: Science

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