Module – IV – Manufacturing Processes,
Energy conversions and Mechanical
Automation
Lecture – 14 – Additive Manufacturing
Course Faculty:
Dr. A. Vinoth Jebaraj, SMEC
Vellore Institute of Technology
Multiple part
consolidation
geometries
Less scrap
Access to
complex
Why Additive
Manufacturing?
Light
weighting
AM Pinnacle in Manufacturing of Complex Shapes
Ref: [Link]
Global market in 3D printing
AM is used to make the most intricate shape and light weight critical
components.
[Link]
AM Process
Support
Structure
Build
Direction
Build Platform
Source: [Link]
AM Process Sequence
Removal & Post Processing
Machine Setup
STL File Manipulation
Transfer to AM Machine
Conversion to STL
CAD [Digitizing model]
Sequence of AM process
Manufacturing Post processing
Digital Phase
Phase phase
Digital phase
Scanning Build
Slicing
strategy orientation
Manufacturing phase
Preparation of Raw Selection of Process
Materials Parameters
Post processing phase
Support Testing and
GD&T Analysis
Removal Evaluation
STL stands for STereoLithography or Standard Tessellation
Language.
STL uses triangles to describe the surfaces to be built. Each triangle
is described as three points and a facet normal vector indicating the
outward side of the triangle.
Source: I. Gibson, D. W. Rosen, B. Stucker, Additive Manufacturing Technologies,
Springer
CAD image
of a teacup
Building using
different layer
thicknesses
Source: I. Gibson, D. W. Rosen, B. Stucker, Additive Manufacturing Technologies,
Springer
7 Categories of Additive Manufacturing
American Society for Testing and Materials (ASTM) classify the
range of Additive Manufacturing processes into 7 categories.
Liquid bonding agent is selectively
deposited to join powder materials.
DED deposit the molten metal onto a
build platform. Mainly used for repairing.
The process in which material (Polymer)
is selectively dispensed through a nozzle.
Droplets of build material are selectively
deposited.
Sheets of material are bonded to form an
object.
Thermal energy selectively fuses regions
of a powder bed.
Liquid photopolymer is selectively cured
by light-activated polymerization.
Source: [Link]
Source: [Link] base/binder-jetting/
centre/
A liquid binder is selectively deposited to join powder particles layer by layer.
Post-processing: Requires sintering, infiltration, or curing to strengthen.
Strengths: Allows for full color printing/ High productivity/ Uses a wide range of
materials.
Typical Materials: Powdered Plastic, Metal, Ceramics, Glass, and Sand.
Source: [Link]
manufacturing-processes
Source: [Link]
Source: [Link]
[Link]
categories-of-additive-manufacturing-technologies
Material (powder or wire) is fed into a focused energy source (laser, electron beam,
plasma arc) and melted at the deposition point.
Strengths: Not limited by direction or axis/ Effective for repairs and adding features/
Multiple materials in a single part/ Highest single-point deposition rates.
Applications: Repairing high-value components (aerospace turbine blades), adding
features to existing parts.
Typical Materials: Metal Wire and Powder, with Ceramics.
Source: [Link]
manufacturing-processes
Source: [Link]
Source: [Link]
coaxial-wire-supply-U82_-y
Source: [Link]
categories-of-additive-manufacturing-technologies
[Link]
Material is pushed through a nozzle and deposited layer by layer.
Strengths: Inexpensive and economical/ Allows for multiple colors/ Can be used in
an office environment/ Parts have good structural properties.
Applications: Prototyping, tooling, low-cost functional parts.
Typical Materials: Thermoplastic Filaments and Pellets (FFF); Liquids, and Slurries
(Syringe Types).
Source: [Link]
manufacturing-processes
Source: [Link]
Source: [Link] categories-of-additive-manufacturing-technologies
Droplets of build material (like inkjet printing) are deposited and cured layer by layer.
Strengths: High level of accuracy/ Allows for full color parts/ Enables multiple
materials in a single part.
Applications: High-resolution models, multi-material and multi-color parts, dental
molds.
Typical Materials: Photopolymers, Polymers, Waxes.
Source: [Link]
manufacturing-processes
Source: [Link]
[Link] base/sheet-lamination/
Sheets of material are bonded together (by adhesive, ultrasonic welding, or thermal
bonding) and cut to shape layer by layer.
Laminated Object Manufacturing (LOM), Ultrasonic Additive Manufacturing
(UAM).
Strengths: High volumetric build rates/ Relatively low cost (non-metals)/ Allows for
combinations of metal foils, including embedding components.
Applications: Large, low-cost prototypes, tooling, metal laminates with embedded
sensors.
Typical Materials: Paper, Plastic Sheets, and Metal Foils/Tapes.
Source: [Link]
manufacturing-processes
Source: [Link]
Source: [Link] categories-of-additive-manufacturing-technologies
Process: A laser or electron beam selectively fuses regions of a powder bed layer by
layer.
Materials: Polymers (nylon, TPU), metals (Ti, Al, SS, Inconel).
Applications: Aerospace, medical implants, automotive lightweight parts.
Strengths: High level of complexity/ Powder acts as support material/ Wide range of
materials.
Source: [Link]
Source: [Link]
Source: [Link] categories-of-additive-manufacturing-technologies
A liquid photopolymer resin is selectively cured (solidified) using a light source (laser,
projector, or LCD screen). SLA (Stereolithography), DLP, LCD Printing
Strengths: High level of accuracy and complexity/ Smooth surface finish/ Accommodates
large build areas.
Typical Materials:
UV-Curable Photopolymer Resins.
Applications: High-detail prototypes, dental models, jewellery casting.
Source: [Link]
Source: [Link]
7 Categories of Additive Manufacturing - Comparison
AM Process Material Form Energy Source Example
Material Extrusion Filament Heat FDM
Vat Photo
Liquid resin Light SLA
polymerization
Powder Bed Fusion Powder Laser/e-beam SLS, SLM
Metal Binder
Binder Jetting Powder + Binder Inkjet
Jetting
Material Jetting Droplets UV light PolyJet
Directed Energy
Wire/Powder Laser/e-beam/arc LENS
Deposition
Adhesive/
Sheet Lamination Sheets LOM
Ultrasonic
Selection of AM process Match the Product Needs to the AM Process
Material + Accuracy + Strength + Volume + Cost → Right AM Process
Material Extrusion
[Fused Deposited Modelling (FDM) or Fused Filament Fabrication (FFF)]
Produced and developed
by Stratasys, USA.
Schematic of Extrusion-
Based Systems
Source: I. Gibson, D. W. Rosen, B. Stucker, Additive Manufacturing Technologies,
Springer
Fused Deposited Modelling (FDM)
Printing Post
Design
Process Processing
Heating of thermoplastic
CAD model generation, filament (ABS, PLA),
STL file conversion, Extrusion of molten Removal of support
Slicing to generate G- filament, Layer by layer structures, Post
Codes, Selection of deposition along with a finishing processes
Process Parameters necessary support
structure
A filament a) of plastic material is
fed through a heated moving head
b) that melts and extrudes it
depositing it, layer after layer,
in the desired shape
Support
structures
FFM
c). A moving platform e) lowers
after each layer is deposited.
Source: [Link]
Limitations of FDM
In FDM process, the disadvantages are mainly in terms of build speed,
accuracy, and material density.
Layer thickness option of 0.078 mm is only available with the highest-cost
machine. Use of this level of precision will lead to longer build times.
It is impossible to create sharp external corners; there will be a radius
equivalent to that of the nozzle at any corner or edge.
The actual shape produced is dependent on the nozzle, acceleration and
deceleration characteristics, and the viscoelastic behavior of the material as
it solidifies.
The speed of an FDM system is reliant on the feed rate and the plotting
speed.
Anisotropic nature of a part’s properties. In almost every case, the strength
in the z-direction is measurably less than the strength in the x–y plane.