"Innovative Single-Piece Pattern Design for 3D

Printing: A Paradigm Shift in Manufacturing"

By
Prof.A.A.Shaikh Gosavi Pranav Dinkarpuri
Department of Mechanical Engineering Department of Mechanical Engineering
Sanjivani College of Engineering, Sanjivani College of Engineering,
Kopargaon,India Kopargaon,India
pranavgosavi84@gmail.com

Abstract further, streamlining the production pipeline and

This research paper explores a groundbreaking approach to paving the way for unprecedented advancements in
pattern design for additive manufacturing, specifically
focusing on the creation of single-piece patterns using 3D
printing technology. Traditional manufacturing processes various industries. This research explores the
often involve multiple components and assembly steps, fundamental principles behind single-piece patterns in
leading to increased production time and costs. In contrast, 3D printing, investigating their potential to redefine
our proposed method leverages the capabilities of 3D the way we conceive, design, and manufacture
printing to fabricate intricate and complex patterns as a products. By examining real-world applications and
single, seamless unit. The study delves into the design case studies, we aim to demonstrate how this cutting-
principles, material considerations, and printing parameters edge approach transcends traditional manufacturing
essential for achieving high-quality single-piece patterns. constraints, offering unparalleled opportunities for
Through a comprehensive analysis of various design customization, cost-effectiveness, and rapid
iterations and experimental results, we demonstrate the prototyping. As we reflect on the progress made over
feasibility of this approach across diverse applications, the past year, it is clear that the fusion of 3D printing
ranging from aerospace components to artistic and and single-piece patterns has already begun reshaping
architectural elements. industries such as aerospace, healthcare, and
Keywords- Additive Manufacturing, 3D Printing , Single automotive manufacturing. This paper
Piece Patterns, Design Innovation ,Manufacturing, navigates through the technological intricacies,
Efficiency, Material Optimization, Prototyping, Complex, challenges, and future prospects of this transformative
Geometry, Sustainable Manufacturing, Digital Fabrication synergy, shedding light on the immense possibilities it
presents for researchers, engineers, and manufacturers
alike.
I. INTRODUCTION
Literature Survey
In recent years, the landscape of manufacturing has Scholars investigate design principles, optimization
undergone a remarkable transformation, with 3D techniques, material considerations, and application-
printing emerging as a disruptive force that challenges specific challenges. Research highlights the importance
traditional production methodologies. This research of geometry, support structures, and orientation in
paper delves into the groundbreaking realm of 3D achieving optimal prints. Additionally, studies explore
printing, specifically focusing on the innovative the evolving role of design in enhancing functionality,
concept of single-piece patterns and their implications reducing costs, and maximizing the potential of 3D
for manufacturing efficiency and design flexibility. As printing technologies across various industries.
we celebrate the one-year anniversary of this research
journey, it becomes increasingly evident that the
integration of 3D printing with single-piece patterns A. III. Pattern
holds the key to unlocking new dimensions in
production capabilities. Traditional manufacturing The “pattern” is essentially a replica of the object about to
techniques often involve intricate and time-consuming be cast. Usually made out of wood, metal or model board,
processes, requiring the assembly of multiple patterns are used to create cavities in molds. It is through
components to create a final product. In contrast, 3D pouring molten metal into these moulds that aluminum
printing has revolutionized this paradigm by enabling castings are created.
the fabrication of complex structures layer by layer,
eliminating the need for assembly. The integration of I.V Single Piece Patterns
single-piece patterns takes this revolution a step

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A single or solid piece pattern is made with out joints, loose
pieces or partings. It has usually one board surface that 2. Draft Allowance: Draft allowance refers to the
serves as a parting surface in the mould. This type of pattern intentional taper or angle added to vertical surfaces of a
is used for a limited number of castings because most of the pattern in manufacturing and pattern making. This
allowance is crucial for facilitating the easy and smooth
moldings operations like providing runners and risers,
removal of the pattern from the mould or casting.
withdrawal of pattern etc. is done by hand. Soil temper
glands of steam engines are made by solid or single piece 3. Machining Allowance: Machining allowance refers
pattern. to the thickness of the metal layer cut from the
machined surface during machining. The M/C
allowance that we gave is around 1mm.

CREO SOFTWARE:

Creo is a family of Computer added design(CAD) apps

supporting product design for discrete manufactures
developed by PTC. Creo, short for Creo Parametric, is
a powerful and intelligent 3D CAD software improved
to deal with the challenges Designing parts in Creo is
easy, and loading assemblies shouldn't be a gamble.
The Creo
Parametric software allows you to retrieve and start
your assembly faster. Anassembly's simplified
representation appears when it's loaded.organizations
face as they design, analyze, and share information.

3D PRINTING MACHINE :

➢ 3D printers use CAD to create 3D objects from a

variety of materials, like molten

ALLOWANCES: Plastic or powders.

Allowance: Allowance is the difference between basic of ➢ 3D printers can come in a variety of shapes and
the mating parts. It is the sizes ranging from equipment that can

Minimum clearance or maximum interference between Fit on a desk to large construction models used in the
parts or the tightest fit between two mating making of 3D-printed houses.

Parts. ➢ 3D printers are machines that specialize in additive

manufacturing i.e. they build parts
I. Shrinkage Allowance
By adding layers of material in successive layers.
II. Draft Allowance
➢ 3D models are used to portray real-world and
conceptual visuals for art,
III. Machining Allowance
Entertainment, simulation and drafting.
1. Shrinkage Allowance: After Solidification of the
metal from additional cooling aspects of pattern PARTS OF MACHINE:
increments, so the pattern design size is greater than
that of the completed cast items. This is known as ➢ Print Bed: The motherboard which is also known as
Shrinkage Allowance. For Aluminium the shrinkage is mainboard or control board. As the Name suggests, this
around 5-6% . component is responsible for maintaining the smooth
It depends on: processing of The machine.

a) Dimensions of casting. ➢ Frame: Frame helps keep all the other components
of your 3D printer together at one Place. It also
b) Design and intricacy of casting.
maintains the stability of the entire machine. If your
c) Resistance of mol to shrinkage. frame is robust, you Will have a more durable 3D
d) Molding materials used. printer.
e) Method of molding used.
f) Pouring temp of the molten metal. ➢ Material: Filament is used for the FDM 3D printers.
Filaments are available in spools. These are heated to
 certain temperature and are liquified to be deposited on
the print Bed.

➢ Motion Controllers: Motion controllers receive

instructions from the mother board About the
movement they must make, while they are the ones
who perform the actual Movements.

➢ There are so many ther parts like

nozzle,motors,heaters,sensors,etc.

STEP TO MAKE HELICAL GEAR:

Start a New Part:

Open Creo Parametric and start a new part file.

Sketch the Profile:

 Use the sketching tools to create the profile of the gear HELICAL GEAR:
tooth. Typically, a helical gear tooth profile is an
involute curve. ➢ Helical gears are one type of cylindrical gears where the
teeth are curved into a helix Shape.
 Sketch the tooth profile on the appropriate plane (front
or top, depending on your preference).
➢ Compared to spur gears (straight teeth), properly
designed helical gears can have a Larger total contact ratio
Create a Helix:
which can improve vibration and noise.
 Create a helical curve that represents the path of the
➢ Badly designed helical gears can be noisier than well
gear teeth. You can use the "Helical Sweep" feature for
designed spur gears.
this.
➢ Some of the industries where the helical gears are
 Define the pitch, number of turns, and other parameters commonly used are: Printing, earth-Moving and fertilizer
for the helix. industries.
Extrude or Sweep:
Extrude or sweep the tooth profile along the helix to create
the 3D geometry of the gear.

Create a Circular Pattern:

Use the circular pattern feature to replicate the gear teeth
around the center axis. Specify the number of teeth and the
angle between them.

Add Fillets and Chamfers:

To improve the strength and aesthetics of the gear, add
fillets to round off sharp edges and chamfers if needed.

Inspect and Validate:

Inspect the gear model using Creo's analysis tools. Check
for interference, clearance, and any other potential issues. PRINTING OF HELICAL GEAR:

Save and Export:

Save your part and assembly files. If needed, export the
files in a Format suitable for your manufacturing process
(e.g., STEP, IGES).
 prototyping technique (Stereo lithography) to enhance the
part quality by Taguchi method”, 2nd International
Conference on Innovations in Automation and
Mechatronics Engineering, ICIAME 2014, Procedia
Technology 14 ( 2014 ) 380 – 389.

[4] Himanshu Khandelwal, Dr. B. Ravi, “3D Printing

Enabled Rapid Manufacture of Metal Parts at Low Cost”,
Technical paper presented at 63nd Indian Foundry
Congress, Noida, February 2015.

[5] Baljinder Singh Shahi, “Advanced Manufacturing

Techniques (3d Printing)”, International Journal of
Mechanical And Production Engineering, ISSN: 2320-
2092, Volume- 4, Issue-4, and Apr.-2016.

Result [6] K. Jianga, Y. Guo, D. L. Bourell, W. Zenga, Z. Li,

The 3D-printed single-piece pattern successfully “Study on selective laser sintering of eucalyptus/PES blend
demonstrates the feasibility of streamlined manufacturing and investment casting technology”, The Seventeenth CIRP
processes, showcasing intricate details and structural Conference on Electro Physical and Chemical Machining
integrity essential for research applications. (ISEM), Procedia CIRP 6 (2013) 510 – 514.Neural
Network Classifier International Journal of Application or
Conclusion Innovation in Engineering & Management
In conclusion, the manufacturing of a single-piece helical (IJAIEM)Volume 2, Issue 6, June 2013.
gear pattern using a 3D printing machine represents a
significant advancement in the field of pattern making for
gears. This innovative approach offers several key benefits
that contribute to the efficiency and precision of the
manufacturing process. The overall production time,
machining time, and pattern making time has come lower
when it is compared to other pattern materials which in
turn reduces the usage of raw materials in pattern making.
From the above results it is clear that the casting obtained
by 3D printed pattern is much superior in surface finish,
dimensional accuracy, exactness of shape. The casting
obtained by this 3D printed pattern made a huge
difference in dimensional accuracy, size and resulted in a
matured surface finish.

Future Scope
The cancer detection system using the machine learning
techniques is much efficient and gives the betterment
results to radiologist and assist them. This enhance with the
additional features for upgrading in the future. On this
processing system to support the radiologist to detect the
affected patients as accurate as the result.

Reference .

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PRINTED PATTERN AND WOODEN PATTERN FOR
SAND CASTING PROCESS International Research
Journal of Engineering and Technology (IRJET)Volume:
06 Issue: 04 | Apr 2019

[2] Pranjal Jain, A. M. Kuthe, “Feasibility Study of

manufacturing using rapid prototyping: FDM Approach”,
The Manufacturing Engineering Society International
Conference, MESIC 2013, Procedia Engineering 63 (2013)
4 – 11.

[3] Raju B S, U Chandra Shekar, K Venkateswarlu, D N

Drakashayani, “Establishment of Process model for rapid