Pillai College of Engineering

Department of Mechanical and Automobile

Engineering

ADDITIVE
MANUFACTURING
MODULEDr.3Richa
Conte
nt
Additive Manufacturing: Product development
cycle and importance of prototyping, types
of
prototypes-principles and advantages,
different types of generative manufacturing
process viz. Vat Photopolymerisation, Material
extrusion, Material Jetting, Binder Jetting,
Powder bed Fusion, Direct energy deposition,
Sheet Lamination.
Introducti
on
Categories of Manufacturing
Process
◻
Subtractive Manufacturing
process
◻
Additive Manufacturing
process
◻
Formative Manufacturing
process
Introducti
on
Additive Vs
Conventional

https://www.3dhubs
.com/knowledge-base/additive-manufacturing-technologies-overview/#introduction
Decision
Criteria

https://www.3dhubs
.com/knowledge-base/additive-manufacturing-technologies-overview/#introduction
Introducti
on
◻ Rapid Prototyping (RP) is a technology that
produces models and prototypes parts from 3D
CAD model data, CT and MRI scan data, and
model data created from 3D object digitizing
systems. - Terry
Wohlers
◻ Additive manufacturing (AM) is new process of
joining materials to make objects from 3D model
data, usually layer upon layer, as opposed to
subtractive manufacturing methodologies.
-ASTM Definition F2792-10
◻ 3D Printing: The fabrication of objects through the
deposition of a material using a print head,
nozzle, or other printer technology. - Terry
Wohlers
Introducti
on

Food
Industry Jewelry
Organ
Introducti
on

Shape Memory
4D Smart Materials
polymers
https://www.youtube
Evolutio
n it provides unique opportunities to investigate the material
quality as it is deposited. Development of in situ monitoring
methodologies is a vital part of the assessment of process
performance and understanding of defects formation
Additive
Manfacturing
Three stages: pre-processing, building & post
processing
Additive
Manufacturing

Functional Principal
◻
The system starts by applying a thin layer of the
powder material to the building platform.
◻
A powerful laser beam then fuses the powder at
exactly the points defined by the computer-
generated component design data.
◻
Platform is then lowered and another layer of
powder is applied.
◻
Once again the materials is fused so as to bond
with the layer below the predefined points.
Pros and
Cons
Material
Classification
1.Polymers
2. Metals
3. Ceramics
4. Composites
Polymers
◻
ABS polymer
◻
Acrylics
◻
Cellulose
◻
Nylon
◻
Polycarbonate
◻
Thermoplastic
polyester
◻
Polyethylene
◻
Polypropylene
◻
Polyvinylchloride
Sample stl
file
STL
file
Advantages
◻
Provides a simple method of representing 3D CAD
data.
◻
A de facto standard and has been used by most
CAD systems and RP systems.
◻
It can provide small and accurate files for data
transfer for certain shapes.
Disadvantages
◻
The STL file is many times larger than the
original CAD data file.
◻
The geometry flaws exist in the STL file.
◻
The subsequent slicing of large STL files can take
many hours.
Additive Manufacturing
Technologies
◻ Vat Polymerization
◻ Material Extrusion
◻ Material Jetting
◻ Binder Jetting
◻ Powder bed fusion
◻ Direct Energy
Deposition
◻ Sheet Lamination

ISO/ASTM 52900-15
Additive Manufacturing
Processes
◻ Vat Polymerization - “ process in
which liquid photopolymer in a vat
is selectively cured by light-
activated polymerization.”

◻ Material Extrusion -“process in which

material is selectively dispensed through
a nozzle or orifice.”

◻ Material Jetting - “ process in which

droplets of build materials are
Additive Manufacturing
Processes
◻ Binder Jetting - “ process in which a liquid
bonding agent is selectively deposited to
join powder materials.”
◻ Powder Bed Fusion - “process in which
thermal energy selectively fuses regions
of a powder bed.”
◻ Direct Energy Deposition - “ process in
which focused thermal energy is used to
fuse materials by melting as they are
being deposited.”
◻ Sheet Lamination - “process in which
 Vat
Polymerization
◻
Laser beam traces a cross-section of the part
pattern on the surface of the liquid resin.
◻
SLA’s elevator
platform descends.
◻
A resin-filled blade
sweeps across the
cross section of the
part, re-coating it with
fresh material.
◻
Immersed in a
chemical bath.
Stereolithography
requires the use of
supporting structures.
Vat
Polymerization
◻ Materials: photocurable resins
◻ Advantages
□
Good dimensional accuracy
□
Good surface finish
◻ Disadvantages:
□
Narrow range of materials
□
Relatively high cost
□
Post curing
◻ Application areas:
□
Prototypes for concept models;
□
Form-fit for assembly tests and process planning;
□
Models for investment casting, replacement of
the wax pattern;
□
Patterns for metal spraying, epoxy molding
and other soft tooling
Material
Extrusion
◻
Fuse deposition modeling (FDM)
◻
Material is drawn through a nozzle,
where it is heated and is then
deposited layer by layer.
◻
First layer is built as nozzle deposits
material where required onto the
cross sectional area.
◻
The following layers
are added on top of
previous layers.
◻
Layers are fused
together upon
deposition as the
material is in a
Material
Extrusion
◻ Materials: thermoplastic material such as wax, ABS
plastic & elastomer
◻ Advantages
□
clean, simple, easy to operate
□
a good variety of material
□
mid range performance/cost
◻ Disadvantages:
□
Relative low accuracy
□
Poor strength in vertical direction
□
Slow for building a mass part
◻ Application areas:
□
Conceptual modeling;
□
Fit, form and functional test;
□
Pattern for investment casting;
□
The MABS (methy methacrylate ABS) material is
particularly suitable for medical applications
Material
Jetting
◻
Drop on demand method.
◻
The print head is positioned above build
platform.
◻
Material is deposited from a nozzle
which moves horizontally across the
build platform.
◻
Material layers
are then cured
or hardened
using ultraviolet
light.
◻
Droplets of
material solidify
and make up
Binder
Jetting
◻
A glue or binder is jetted from an inkjet
style print head.
◻
Roller spreads a new layer of powder on
top of the previous layer.
◻
The subsequent
layers is then
printed and is
stitched to the
previous layer by
the jetted binder.
◻
The remaining
loose powder in
the bed supports
overhanging
Powder Bed
Fusion
◻
Selective laser sintering (SLS)
◻
Selective laser melting (SLM)
◻
Electron beam melting (EBM)
Process:
◻
A layer, typically 0.1mm thick of material is
spread over the build platform.
◻
The SLS machine
preheats the bulk
powder material in the
powder bed.
◻
A laser fuses the first
layer.
◻
A new layer of
powder is spread.
◻
Further layers or cross
sections are fused and
added.
Powder Bed
Fusion
◻ Materials: powder material such as nylon, wax, polycarbonate,
metal, ceramic, elastomer, etc.
◻ Advantages
□
Large variety of material available
□
Produced in short time
□
No additional support required
□
No post curing required
◻ Disadvantages:
□
Heat up powder & cool down part
□
Smoothness of surface restricted
□
Expensive running cost
□
Toxic gases generated
◻ Application areas:
□
Visual representation;
□
Durable enough for most functional tests;
□
Pattern for making soft tooling, casting;
□
Direct manufacture of metal mould;
□
Small batch production run
Direct Energy
Deposition
Consists of a nozzle mounted on a multi axis arm.
◻

◻
Nozzle can move in multiple directions.
◻
Material is melted upon deposition with a laser or
electron beam.
Process:
1. A4 or 5 axis with nozzle
moves around a fixed
object.
2. Material is deposited
from the nozzle onto
existing surfaces of the
object.
3. Material is either
provided in wire or
powder form.
4. Material is melted using a
laser, electron beam or
plasma are upon
Sheet
Lamination
◻
Metal sheets are used.
◻
Laser beam cuts the contour of
each layer.
◻
Glue activated by hot rollers.
Process - laminated Object
Manufacturing:
1. The material is
positioned in place
on the cutting bed.
2. The material is
bonded in place,
over the previous
layer, using the
adhesive.
Sheet
Lamination
◻ Materials: sheet material such as paper, plastic, ceramic,
composite etc
◻ Advantages
□
A relatively high speed process
□
No post curing required
□
No support structure required
□
Simple to use
◻ Disadvantages:
□
The most commonly used material is only paper
□
Must be post processed immediately
□
Restricted to build complex parts
□
Fire hazard occasionally happened
◻ Application areas:
□
Visual representation;
□
Concept modeling;
□
Pattern for sand casting
Fused Deposition Modeling -
FDM
◻ Need .stl file
□ 3D Modeling Software
□ Online
Community/Library
◻ GRABCAD
□ Login required
□ .stl of all models
available
□ https://grabcad.com/lib
rary
◻ Thingiverse
Fused Deposition Modeling -
FDM
◻ Slicing
Software
□ Ultimaker Cura
□ Open source
slicing
application
for 3D
printers
Steriolithography Apparatus
- SLA
◻ Chitubox SLICING
Software
Printed
Part
Infill
Density
FDM Vs SLA Printed
Parts
3D from 2D
images
◻ Medical Application
◻ CT (Computerized Tomography )
□ Scan combines a series of X-ray images taken from
different angles around the body and uses computer
processing to create cross-sectional images (slices) of
the bones, blood vessels and soft tissues inside your
body.
□ CT scan images provide more-detailed information

◻
than
MRI plain X-rays
(Magnetic do
Resonance More Detailed
Images
Imaging)
□ Uses strong magnetic fields, magnetic field
gradients, and radio waves to generate images
of the organs in the body.
◻ DICOM (Digital Imaging and COmmunications
3D
Slicer
◻ Open source software platform for
medical image informatics, image
processing, and
three-dimensional visualization
Thank You
!!