Additive Manufacturing (3D Printing)

Additive manufacturing (AM) as defined by the ISO/ASTM 52900 terminology standard is

the process of joining materials to make parts from 3D model data. Usually, material is joined
layer upon layer, as opposed to subtractive and formative methods of manufacturing. Other
terms for AM include 3D printing, additive fabrication, direct digital manufacturing, freeform
fabrication, solid freeform fabrication, rapid manufacturing, and rapid prototyping.
AM is used to build models, prototypes, patterns, tooling, and production parts. The parts are
produced using 3D models created by computer-aided design (CAD) software, 3D scanning
systems, medical imaging equipment, and even video games. Design and manufacturing
organizations use AM parts for products in the consumer, industrial, medical, and military
sectors, to name a few. Any industrial sector can benefit from adopting AM.
As a tool for product development, AM can reduce time to market, improve product quality,
and reduce costs. Quick product iterations streamline and expedite the product development
process. As a visualization tool, AM helps companies reduce the likelihood of delivering a
flawed product. 3D-printed models allow companies to gain early feedback from
management, experts, customers, and other stakeholders.
AM is increasingly being used to produce final parts. Companies benefit by being able to
reduce inventory as AM can produce parts on-demand. The other benefits for AM include
enhancing performance, which can include part consolidation, topology optimization,
conformal cooling channels, and internal cellular or lattice structures.

The Seven AM Processes

1. Material extrusion (MEX)
This is a 3D printing process in which material is selectively dispensed through a nozzle or
orifice. The moving nozzle, also called an extruder, deposits a layer of materials and then
either the extruder or build platform raise or lower, respectively, and the process is repeated.
The part’s shape is determined by a pre-loaded file created by a software called a “slicer.”
MEX is capable of printing different materials, yet the most popular are thermoplastics in
filament form (e.g., ABS, nylon, PEEK, PLA, etc.). Composite and other filled materials,
such as carbon-filled and glass-filled filaments, are also becoming more common. MEX can
print paste-like materials, such as concrete, ceramics, or foods such as chocolate or dough.
This process requires sacrificial support material for overhanging features.
2. Vat photopolymerization (VPP)
This is a 3D printing process in which liquid photopolymer in a vat is selectively cured by
light-activated polymerization. The printing process begins with the resin in a vat (i.e., tank
or build volume). The two common types of VPP use either a laser or light-emitting diodes
(LEDs) coupled with digital light processing (DLP) as the energy source to cure the resin.
Laser-based VPP systems typically cure one layer before the build volume is lowered and a
new layer of liquid photopolymer is spread across the build area. Typically, DLP systems
project light from below the vat and cure the photosensitive resin through an optical window.
VPP systems are desirable for high-resolution parts at a reasonable cost. The process requires
a secondary curing and washing step for post-processing. VPP requires sacrificial support
material for overhanging features.
3. Powder bed fusion (PBF)
This is a process in which thermal energy selectively fuses regions of a powder bed. Thermal
energy from a laser or electron beam melts a portion or all of the powder that the beam
contacts. The area adheres to the previous layer and becomes solid as the material cools.
Once the layer has been fused, a new layer of powder is added.
A wide range of polymers and metals are suitable for PBF. Typically, polymers are semi-
crystalline thermoplastics. For polymers, the unfused, loose powder surrounding the part
serves as a support material. For metal PBF, support structures are required to anchor parts
and features to the build plate. This process can lead to significant thermal stresses and heat
treatment is typically required for metal PBF.
4. Binder jetting (BJT)
This is an AM process in which a liquid bonding agent is selectively deposited to join powder
materials. The process starts with a layer of powder, which can be a polymer, metal, ceramic,
or sand. A print head deposits droplets of a binding agent onto the material, fusing the
particles together in a pre-determined pattern. Once a layer is complete, the print platform
moves downward, and a new layer of powder is spread onto the build area.
Parts made using BJT typically require post-processing to improve their mechanical
properties. This can involve adding an additional adhesive substance or placing the part in an
oven to sinter the particles.
5. Material jetting (MJT)
In this process, droplets of feedstock material are selectively deposited using inkjet print
heads. The material, which is typically photopolymers or wax-like substances, are cured and
solidified with UV light. Once a layer is cured, the nozzles in the print head will deposit new
material on top of it, one layer at a time.
MJT parts require supports, which are often printed with a dissolvable material and removed
during post-processing. This process can print graded material combinations, producing
different material properties or colors throughout the part.
6. Directed energy deposition (DED)
The DED is defined as a process in which focused thermal energy is used to fuse materials by
melting as they are being deposited. The feedstock used for DED is either a metal powder or
wire. This technology involves a nozzle mounted on a multi-axis arm and is sometimes
combined with CNC milling. The process produces near-net-shape parts and usually requires
machining to achieve required tolerances.
DED offers unique capabilities, including depositing more than one material simultaneously.
In addition to printing new parts, DED can repair damaged parts by depositing material
directly onto them.
 7. Sheet lamination (SHL)
This is a process in which sheets of material are bonded to form a part. This process can use a
variety of materials, including metal, paper, polymers, or composites. SHL involves a layer of
material being adhered to another using an adhesive or welding process. Layer contours are
typically generated by a machining process either before or after a layer or material is
deposited.
Parts produced with SHL require different design parameters as internal cavities can be
challenging, if not impossible, to remove material from. Due to the limited head required for
this process, electronics and other low-melting-point materials can be embedded into the part.

Materials for Additive Manufacturing

• Polymers
Many polymers are available for AM, yet the offerings are still small compared to
conventional processes (i.e., formative and subtractive manufacturing). Materials are
typically selected by their properties, such as tensile strength, rigidity, biocompatibility, glass
transition temperature, color, and transparency. Additional properties include moisture
resistance, sterilization, fire retardancy, and smoke and toxicity emissions. Materials range
from hard and stiff to soft, rubber-like elastomers.
Polymers are classified into two groups based on their behavior at high temperatures.
Thermoplastics can be repeatedly melted, cooled, and solidified. They retain their properties,
although some degradation can occur, particularly with repeated high-temperature exposure.
Thermoset polymers are permanently cured once they are polymerized. After polymerization,
thermosets do not melt like a thermoplastic would at high temperatures. Photopolymers, like
those used in vat photopolymerization (VPP) and material jetting (MJT), are liquid thermoset
resins that are polymerized when exposed to certain wavelengths of light.
Commonly used polymers include polycarbonate, polyamides (PA), and nylon, just to name a
few. A few companies have developed 3D printers that extrude silicone rubber. The material
is printed as a liquid and cures before the next layer is deposited. Other materials have been
certified as biocompatible or food-grade. Some companies offer exotic filaments such as
clay-filled and bone-like materials. Metal-filled PLA materials also exist, as do filaments
composed of metal powder with PLA used as the binder.
• Metals
The range of metals and metal alloys available for AM continues to grow. Choices include,
but are not limited to, tool steels, stainless steels, titanium, aluminum, copper, and nickel-
based alloys. Specialty metals for AM include gold, silver, platinum, palladium, tantalum,
tungsten, and niobium. Many of these materials have been available for some time, yet their
use for final part production has been limited. This is mainly due to the qualification and
certification requirements in aerospace, healthcare, energy, and other sectors.
Most metal AM processes involve rapid melting and solidification of materials, which can
lead to cracking in alloys not typically considered weldable. Metal AM processes include
powder bed fusion (PBF), binder jetting (BJT), sheet lamination (SHL), directed energy
deposition (DED), and more recently material extrusion (MEX).
Most metal AM parts require some form of post-processing, such as heat treatment or
machining, to achieve desirable properties. Both BJT and MEX require a debinding and
sintering step to achieve near-full density parts.
• Ceramics and other materials
Several companies offer ceramics, blends, and other specialty materials. They can include
photopolymers filled with ceramic particles. To produce fully or near fully dense parts, they
are placed in a furnace, which burns out the binder and sinters the ceramic. BJT systems can
also produce glass and ceramic parts.
Biocompatible materials are of growing interest in AM. Some metals, such as titanium alloy
Ti-6Al-4V, can be implanted into human patients. The polymers PEEK and PEKK are also
used to produce medical implants.
Additional materials that can be used in 3D printing include graphene, paper, concrete, foam,
and food products such as chocolate.

Applications Of Additive Manufacturing

➢ Prototypes
3D printing’s earliest applications were for rapid prototyping. Stereolithography offered
designers and engineers a faster, more digital route to design a product based on easy
iteration. While the technology still has a stronghold in prototyping, additive manufacturing
(AM) has advanced far beyond this with the maturation of various technologies and
expansion of its materials envelope.
➢ Tooling
Additive manufacturing’s ability to quickly build complex geometries has made it popular for
tooling applications. 3D printed hand tools, gages, work-holding items for machining, robot
grippers and end-of-arm-tooling (EOAT), fixtures for CMM measurement, and much more
are becoming common sights in machine shops, molding facilities and OEM factories.
3D printing can also be used to build tools that directly or indirectly form the geometry of a
final production piece. Examples include tooling for composites layup, thermoforming,
vacuum forming, casting (both sacrificial patterns and sand tools themselves), sheet metal
bending and injection molding. In some cases, 3D printing brings additional benefits to the
production process, as is the case with conformal cooling channels in injection molds; more
efficient cooling leads to faster cycle times and improved part quality.
➢ Production Parts
Faster 3D printers and more capable materials have helped accelerate AM into production
applications, where 3D printing serves as a bridge or stop-gap method; a solution for spare or
one-off parts; or, increasingly, the sole production process for an end-use part.

Additive Manufacturing Workflow

3D printing is only one step in the overall additive manufacturing workflow. For most AM
production applications, the workflow will look something like this:
 1. Design the part. Design may mean modifying an existing design for 3D printing, or
starting from scratch with a true design for additive manufacturing (DFAM) mindset.
Computer simulation, generative design and topology optimization can all be applied
to optimize the function of the part. Printing process and material selection usually
occurs in the initial design step.
2. Plan the build. Depending on the intended 3D printing technology, this step may
entail selecting part orientation, adding support structures, packing or nesting multiple
parts together, and setting printer parameters such as layer height, laser spot size, feed
rate, etc.
3. 3D print the part. A 3D printing build might take anywhere from minutes to days.
4. Postprocess the part. Depending on the process, postprocessing could entail
unpacking powder, prying or cutting parts from a build platform, cleaning, curing,
heat treating, hot isostatic pressing (HIPping), etc.
5. Finish the part. Many 3D printed tools and production parts will require further
finishing to arrive at their completed state. Finishing steps might include machining
surfaces, drilling or tapping holes, dyeing, coating or painting, and possibly welding
or assembly with other parts.
6. Inspect the part. Some parts can be evaluated with CMM measurement or 3D
scanning; those with complex internal features may require X-ray or CT scanning.
Different parts and applications may call for fewer or more steps. A hand tool made with
fused filament fabrication (FFF) may not require any additional postprocessing once removed
from the build plate. Parts with particularly stringent requirements, however, may require
many more steps.

Advantages of Additive Manufacturing

3D printing first gained traction as a tool for rapid prototyping, but as the technology has
advanced, there are now numerous advantages to choosing additive manufacturing for
production. Here are some of them:
Design freedom
Additive manufacturing is not limited by molds, fixturing or other hard tooling
considerations. It is possible to 3D print complex shapes with organic geometries; conformal
passageways; nonround holes; lattice structures; and other optimized shapes that would be
challenging or impossible to produce conventionally.
Material options
Additive manufacturing makes it possible to utilize materials that might be difficult to cut or
form with other processes. Titanium, Inconel and ceramics are among the materials that are
challenging to machine for instance, but relatively easy to 3D print. AM also provides the
opportunity for multimaterial components that apply high-value materials only in the places
they are needed, and better control over reinforcements like continuous carbon fiber.
Increased accessibility to high-performance polymers and polymer composites through 3D
printing also means that many items that might have been metal in the past can now be
produced additively, with less waste, and from a lighter and often cheaper material.
Assembly consolidation
Because of the complexity enabled by 3D printing, it is often possible to combine multiple
parts of an assembly into a single 3D printed component. Assembly consolidation may be as
simple as joining two halves of a hollow piece, or as sophisticated as combining what might
have been dozens of individual parts previously. Consolidation can even include embedded
items like metal inserts and sensors. When applied this way, AM can dramatically reduce the
number of manufacturing operations, fasteners, glue, hand labour, suppliers and overall
pieces needed to produce a particular component. As a side benefit, limiting the number of
overall materials can also make such items easier to recycle.
Lightweighting
Assembly consolidation and design possibilities through additive manufacturing make it
possible to create very lightweight structures. Because AM applies material only where it is
needed, components need not carry any extra mass; adding additional stock only increases
printing time and material consumption. When combined with topology optimization or
generative design strategies, 3D printing can massively reduce the weight of brackets, brake
panels, combustion chambers, cutting tools and much more.
Speed
While 3D printing an individual part may be slower than machining, casting, moulding or
forging one, these conventional processes require tooling and setup that 3D printing does not.
In cases where no tool is available, or there is no time to wait for one to be developed,
additive manufacturing can be applied to manufacture parts directly. The time savings can be
significant, with AM delivering parts in days or weeks compared to the months it might take
to have a mold tool produced, for instance.
Local or distributed manufacturing
Related to the above point regarding speed, 3D printing is increasingly available closer to the
need than a conventional supplier might be. In the face of supply chain disruptions and
unpredictable global shipping, AM can be the way to produce needed parts locally and
quickly. Various entities are working to develop distributed manufacturing networks that will
be able to send part files to a 3D printing facility close to the customer, reducing the
environmental impact of shipping for these goods. IP protection is a concern for traveling part
files, but efforts to incorporate security measures like biometrics and blockchain are bringing
solutions.
Less waste
Along with literally producing less waste in the form of scrap during manufacturing, 3D
printing also supports on-demand manufacturing meaning that parts can be made only when
needed. Designs can live in a “digital inventory” rather than a physical one, so that there is no
physical excess to dispose of if it goes unused. On-demand production is generally a more
sustainable method of manufacturing as well.
Cost savings
While not universally true, additive manufacturing can be a more cost-effective method of
production. For an inventor looking to bring an idea to market, or an OEM looking to soft
launch a product, AM offers an affordable way to manufacture initial runs without making the
investment into expensive tooling or equipment. If the demand is low, the risk in testing the
market is much less; but if the product sells, the creator can always ramp up using a
conventional process, with the added reassurance of customer feedback already under his or
her belt.
Mass customization
Additive manufacturing also makes mass customization more affordable and easier to apply.
With no need for hard tooling, it is possible to create tweakable base designs
for shoes, furniture, hearing aids, mouthguards, orthotics, splints and more that can be
customized to the specific customer or patient with no added cost in manufacturing.

Powder Bed Fusion (PBF)

The Powder Bed Fusion process includes the following commonly used printing techniques:
Direct metal laser sintering (DMLS), Electron beam melting (EBM), Selective heat sintering
(SHS), Selective laser melting (SLM) and Selective laser sintering (SLS).
Powder bed fusion (PBF) methods use either a laser or electron beam to melt and fuse
material powder together. Electron beam melting (EBM), methods require a vacuum but can
be used with metals and alloys in the creation of functional parts. All PBF processes involve
the spreading of the powder material over previous layers. There are different mechanisms to
enable this, including a roller or a blade. A hopper or a reservoir below of aside the bed
provides fresh material supply. Direct metal laser sintering (DMLS) is the same as SLS, but
with the use of metals and not plastics. The process sinters the powder, layer by layer.
Selective Heat Sintering differs from other processes by way of using a heated thermal print
head to fuse powder material together. As before, layers are added with a roller in between
fusion of layers. A platform lowers the model accordingly.

Powder Bed Fusion--Step by Step

i. A layer, typically 0.1mm thick of material is spread over the build platform.
ii. A laser fuses the first layer or first cross section of the model.
iii. A new layer of powder is spread across the previous layer using a roller.
iv. Further layers or cross sections are fused and added.
v. The process repeats until the entire model is created. Loose, unfused powder is
remains in position but is removed during post processing.

Types of powder bed fusion (PBF) printing techniques

a) Selective laser sintering (SLS): SLS machines are made up of three components
(Gibson et al., 2010): a heat source to fuse the material, a method to control this heat
source and a mechanism to add new layers of material over the previous. The SLS
process benefits from requiring no additional support structure, as the powder material
provides adequate model support throughout the build process. The build platform is
within a temperature controlled chamber, where the temperature is usually a few
degrees below that of the material melting point, reducing the dependency of the laser
 to fuse layers together. The chamber is often filled with nitrogen to maximise
oxidation and end quality of the model. Models require a cool down period to ensure a
high tolerance and quality of fusion. Some machines monitor the temperature layer by
layer and adapt the power and wattage of the laser respectively to improve quality.
b) Selective Laser Melting (SLM): Compared to SLS, SLM is often faster (Gibson et
al., 2010), but requires the use of an inert gas, has higher energy costs and typically
has a poor energy efficiency of 10 to 20 % (Gibson et al., 2010). The process uses
either a roller or a blade to spread new layers of powder over previous layers. When a
blade is sed, it is often vibrated to encourage a more even distribution of powder
(Gibson et al., 2010). A hopper or a reservoir below or aside the bed provides a fresh
material supply.
c) Selective Heat Sintering (SHS): It uses a heated thermal printhead to fuse powder
material together. As before, layers are added with a roller in-between fusion of
layers. The process is used in creating concept prototypes and less so structural
components. The use of a thermal print head and not a laser benefits the process by
reducing significantly the heat and power levels required. Thermoplastics powders are
used and as before act as support material. The ‘Blue printer’ is a desktop 3D printer
that uses the SHS technology, with a build chamber of 200mm x 160mm x 140mm,
print speed of 2-3mm/hour and a layer thickness of 0.1mm (Blue Printer SHS , 2014).
d) Direct Metal Laser Sintering (DMLS): It uses the same process as SLS, but with the
use of metals and not plastic powders. The process sinters the powder, layer by layer
and a range of engineering metals are available.
e) Electron Beam Melting (EBM): Layers are fused using an electron beam to melt
metal powders. Machine manufacturer Arcam used electromagnetic coils to control
the beam and a vacuum pressure of 1×10-5 mba (EBM Arcam , 2014). EBM provides
models with very good strength properties due to an even temperature distribution of
during fusion (Chua et al., 2010). The high quality and finish that the process allows
for makes it suited to the manufacture of high standard parts used in aeroplanes and
medical applications. The process offers a number of benefits over traditional
methods of implant creation, including hip stem prosthesis (Agaruala, 1995).
Compared to CNC machining, using EBM with titanium and a layer thickness of
0.1mm, can achieve better results, in an faster time and can reduce the cost by up to
35%.
Post processing requirements include removing excess powder and further cleaning and CNC
work. One advantage and common aim of post processing is to increase the density and
therefore the structural strength of a part. Liquid phase sintering is a method of melting the
metal powder or powder combination in order to achieve homogenization and a more
continuous microstructure throughout the material, however, shrinking during the process
must be accounted for. Hot isotactic pressing is another method to increase density; a vacuum
sealed chamber is used to exert high pressures and temperatures of the material. Although this
is an effective technique to improve strength, the trade-off is a longer and more expensive
build time.

Materials for PBF

The Powder bed fusion process uses any powder based materials, but common metals and
polymers used are:
SHS: Nylon DMLS, SLS, SLM: Stainless Steel, Titainium, Aluminium, Cobalt Chrome, Steel
EBM: titanum, Cobalt Chrome, ss, al and copper.

Pros and Cons of PBF

Advantages:
➢ Relatively inexpensive
➢ Suitable for visual models and prototypes
➢ (SHS) Ability to integrate technology into small scale, office sized machine
➢ Powder acts as an integrated support structure
➢ Large range of material options
Disadvantages:
➢ Relatively slow speed (SHS)
➢ Lack of structural properties in materials
➢ Size limitations
➢ High power usage
➢ Finish is dependent on powder grain size

Equipment Used for PBF

1. 3D Systems DMP Flex 100
3D Systems’ patented layer compacting technology allows using smaller particles, which in
turn helps to generate the finest feature detail available in the market and thinnest possible
wall thicknesses. The typical accuracy on our small metal parts is +/-50 μm (+/-0.002 inches),
on large parts +/-0.2%. Repeatability from part to part is approximately 20 μm (0.0008
inches). 3DXpert, 3D Systems’ all-in-one software solution for Design for Additive
Manufacturing (DfAM), is included with the DMP Flex 100 to ensure a streamlined and
repeatable process for high quality optimized prints.
DMP Flex 100 metal printer has enough power to process a broader material selection
spectrum including different grades of Titanium. 3D Systems offers LaserForm CoCr (B) and
LaserForm17-4PH (B) with extensively developed, tested and optimized print databases.
Further LaserForm materials for use with DMP Flex 100 are in development.
DMP Flex 100 solution features a build volume of 100 x 100 x 90 mm (3.94 x 3.94 x 3.54
in), a 100W laser, 3DXpert All-in-One Software Solution for Metal Additive Manufacturing
and a portfolio of qualified LaserForm metal powders. The DMP Flex 100 metal printer
offers the flexibility of manual material loading.
The smallest of the DMP line, DMP Flex 100 is designed as the entry point to 3D printed
metal manufacturing of small, complex fine detail metal parts at high quality using Direct
Metal Printing (DMP).
Applications
• Small, complex precision parts
• Research and development
• Simplified assemblies/reduced number of parts
 • Reduced weight/lightweight design
• Enhanced fluid flow
• Jewelry manufacturing
Benefits
• Exceptional surface finish and resolution
• Prints parts that others struggle to print
• Minimal waste of materials
• Consistently high accuracy parts even on first-time builds
• Ease of use ‒ intuitive workflow
• Complete solution (printers, materials, software and application support)
Tech Specs
• Uses Direct Metal Printing (DMP) technology
• Build volume (W x D x H): 100 x 100 x 90 mm (3.94 x 3.94 x 3.54 in) –height
inclusive of build plate
• Surface finish quality of up to 5 Ra μm (200 Ra micro inches)
• High precision and repeatability
• Intuitive 3DXpert software for part set-up and production
• LaserForm materials with certified parameters
Commonly Used Materials for the DMP Flex 100
• LaserForm 316L (B)
• LaserForm 17-4PH (B)
• LaserForm CoCr (B) or (C)

2. Vibratory Sieve Shaker AS 200 basic

Sieve shakers are devices designed to help promote particle movement through a stack of
sieves, facilitating accurate particle separation. As the particle separate, they are retained on
the various sieves depending on their size, providing insight into the average particle size of
your sample.
The vibratory sieve shakers of the series AS 200 are used in research & development, quality
control of raw materials, interim and finished products as well as in production monitoring.
The controllable electromagnetic drive offers an optimal adaption for every product. Sharp
fractions are obtained even after short sieving times.
FEATURES

Applications separation, fractioning, particle size determination

Field of application agriculture, biology, chemistry / plastics, construction materials, engineering /

electronics, environment / recycling, food, geology / metallurgy, glass /
ceramics, medicine / pharmaceuticals

Feed material powders, bulk materials, suspensions

Measuring range* 20 µm - 25 mm

Sieving motion throwing motion with angular momentum

Max. batch / feed capacity 3 kg

Max. number of fractions 9 / 17

Max. mass of sieve stack 4 kg

Amplitude digital, 1 - 100% (0 - 3 mm)

Controlled amplitude -

Time display digital, 1 - 99 min

Suitable for dry sieving Yes

Suitable for wet sieving Yes

Suitable sieve diameters 100 mm / 200 mm / 203 mm (8")

Max. height of sieve stack 510 mm

Clamping devices standard, "comfort", each for wet and dry sieving

Protection code IP 21

Electrical supply data different voltages

Power connection 1-phase

WxHxD 417 x 212 x 384 mm

Net weight ~ 35 kg

3. Ultrasonic Cleaner
Ultrasonic cleaning is a post-processing step in additive manufacturing (3D printing) that
removes support material and cleans components.
Ultrasonic cleaners use high frequency sound waves (produced by an ultrasonic transducer)
to create cavitation bubbles in a cleaning liquid. When the ultrasonic cavitation bubbles
collapse, they create a cleaning action that can remove debris, dirt, grease, and other deposits
from surfaces.
The ultrasonic energy produced by high frequency sound waves helps to loosen deposits that
are difficult to remove with traditional cleaning methods. As a result, ultrasonic cleaners can
be used for a wide variety of cleaning applications. Most ultrasonic cleaners operate at
frequencies between 20 kHz and 400 kHz and typically use water or a water-based solution as
the cleaning fluid.
Support material removal: Ultrasonic cleaning can remove support material that's added
during printing, which can be made from the same material as the 3D print or a separate
material.
Component cleaning: Ultrasonic cleaning can clean components with complex geometries
and hard-to-reach areas. It uses high-frequency sound waves to create bubbles that implode
and dislodge residue.
Avoiding malfunctions: Ultrasonic cleaning can help avoid malfunctions and errors.
4. Bead Blaster
Bead blasting is a post-processing technique used in additive manufacturing (AM) to clean,
polish, and improve the surface of a part:
• Cleaning: Removes coatings, corrosion, and contaminants
• Polishing: Leaves a smooth, clean, and aesthetically pleasing surface
• Deburring: Smooths rough edges or ridges
• Surface preparation: Prepares the surface for other finishes, such as paint or powder
coating
• Cosmetic finishing: Adds aesthetic features to components
• Surface uniformity: Improves the uniformity of surfaces for cosmetic and mechanical
needs
To bead blast a part, hold it about four inches away from the nozzle and move it in and out of
the bead flow. We can use an air blaster to remove any remaining material.
5. Oven
Ovens play a key role in additive manufacturing by improving the quality and mechanical
properties of the final product:
Heat treat ovens
Remove residual stress and improve the microstructure of metal parts. Vacuum heat treat
ovens are particularly useful for hardening tool steels and titanium.
Vacuum sintering furnaces
Allow for the cost-effective 3D metal printing of parts and prototypes. During the sintering
process, parts are removed from the powder bed and placed in an oven to make them fully
dense and hard.
Industrial ovens
Designed for drying pharmaceutical tablets, which is a critical step in the production process.
Modified atmosphere chamber furnaces
Provide a heated volume with a controlled atmosphere to relieve stress from additive
manufactured components.