Mahatma Education Society’s

Pillai College of Engineering

Department of Mechanical and Automobile Engineering

ADDITIVE MANUFACTURING
MODULE 3
Dr. Richa Agrawal
Content
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.
Introduction
Categories of Manufacturing Process
◻ Subtractive Manufacturing process
◻ Additive Manufacturing process
◻ Formative Manufacturing process
Introduction
 Additive Vs Conventional

[Link]
 Decision Criteria

[Link]
Introduction
◻ 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

Also known as Solid Freeform Fabrication (SFF) or Layer

Manufacturing (LM)
Introduction

Food Industry

Organ Printing Jewelry

Introduction

Shape Memory polymers

4D Printing Smart Materials
[Link]
Evolution
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 selectively deposited.”
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 sheets of
materials are bonded to form an object.”
 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
melted state.
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
the first layer.
◻ Platform descends.
◻ Good accuracy and
surface finishes
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
structures.
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.
◻ The process repeats until the
entire model is created.
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 deposition.
5. Further materials is added layer
by layer and solidifies, creating
or repairing new material
features on the existing object.
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.
3. The required shape is
then cut from the layer, by
laser or knife.
4. The next layer is added.
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
[Link]
◻ Thingiverse
[Link]
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 plain
X-rays do
◻ MRI (Magnetic Resonance Imaging) More Detailed Images
Uses strong magnetic fields, magnetic field gradients, and
radio waves to generate images of the organs in the body.
◻ DICOM (Digital Imaging and COmmunications in Medicine)
[Link]
3D Slicer
◻ Open source software platform for medical image
informatics, image processing, and
three-dimensional visualization
Thank You !!