ADDITIVE MANUFACTURING
Course Code: MF8071
Department of Mechanical Engineering
Ramco Institute of Technology, Rajapalayam
TEXT BOOKS:
1 Chua C.K., Leong K.F., and Lim C.S., “Rapid prototyping: Principles and applications”, Third
edition, World Scientific Publishers, 2010.
2 Ian Gibson, David [Link], Brent Stucker “Additive Manufacturing Technologies: Rapid
Prototyping to Direct Digital Manufacturing” Springer , 2010.
REFERENCES:
1 Andreas Gebhardt “Understanding Additive Manufacturing: Rapid Prototyping, Rapid
Manufacturing”
Hanser Gardner Publication 2011.
2 Kamrani A.K. and Nasr E.A., “Rapid Prototyping: Theory and practice”, Springer, 2006.
3 Liou L.W. and Liou F.W., “Rapid Prototyping and Engineering applications :A tool box for
prototype
COURSE OUTCOME:
On completion of this course, students will learn about
Working principle and construction of Additive Manufacturing
technologies,
AM potential to support design and manufacturing,
Modern development in additive manufacturing process
Case studies relevant to mass customized manufacturing.
[Link] John Britto
Assistant Professor ([Link].)
Department of Mechanical Engineering
Ramco Institute of Technology,
Rajapalayam
ADDITIVE MANUFACTURING
UNIT I INTRODUCTION
Overview – Need - Development of Additive Manufacturing Technology -Principle – AM Process Chain-
Classification –Rapid Prototyping- Rapid Tooling – Rapid Manufacturing – Applications- Benefits –Case studies..
History Of 3D Printing
1984 2010 3D Printed human body vessel
Charles Hull invents SLA 3D Printers
1990 Stratasys invents FDM technology 2013 3D Printed houses
1999 3D Printed scaffolding for growing cells 2014 Zero gravity 3D printer for space
2002 3D Printed functional animal kidney 2015 CLIP technology launched
2015 Rep-Rap project 2016 HP launches new 3D Printer
Conventional Manufacturing vs Additive Manufacturing Technology
Subtractive vs Additive Manufacturing Technology
Overview & History of Additive Manufacturing Technology
Historical development of Rapid Prototyping and related technologies
Year of
Technology
Inception
1770 Mechanization
1946 First Computer
1952 First Numerical Control (NC) Machine Tool
1960 First commercial Laser
1961 First commercial Robot
1963 First Interactive Graphics System
(early version of Computer-Aided Design)
1988 First commercial Rapid Prototyping System
Applications
TYPES OF MATERIALS FOR 3D ADDITIVE MANUFACTURING
3D PRINTING IN FOOD PRODUCTION
TERMINOLOGY
1. “Rapid” 3. “Layer”
• Rapid Manufacturing • Layer Based Manufacturing
• Rapid Technology • Layer Oriented Manufacturing
• Rapid Prototyping • Layer Manufacturing
• Rapid Tooling 4. “Digital”
2. “Additive” • Digital Fabrication
• Additive Manufacturing (AM) • Digital Mock-up
• Additive Layer Manufacturing (ALM) 5. “Direct”
• Additive Digital Manufacturing (DM) • Direct Manufacturing
• Direct Tooling
ADDITIVE MANUFACTURING – LAYERED MANUFACTURING
Customization
• Spoon
Mass Customization
• Camera
• Shoe
• Chairs
• Car
Rapid Manufacturing
The customer feedback or requirements converted it into a digital form; and that digital form is given
directly to the machine. The parts are produced and directly moved towards application.
• Rapid manufacturing is more towards mass customization where cost is not to be compromised, but things
have to be produced to the customers satisfaction with the highest integrity, that is Rapid Manufacturing.
Rapid Manufacturing Status
Gebhardt understanding additive manufacturing,2012
Advantages Of 3D Printing
1 No need for CNC Machining / Tooling / Die Creation
2 No limitations on complexity / creativity
3 Shorter time to market
4 Possibility of mass customization
5 Multi-material options
Limitations Of 3D Printing
1 3D Printing is a slow process
2 Surface finish issues, need post processing
3 Applicable only for smaller quantities
4 Limited by the types of input materials
5 Failure rate is still quite high
3D Printing vs. Traditional Manufacturing
Customization Intricate Parts Prototype Cost 1st Part Lead Time
10
9 9 9
7
5 5
4
Cost/Low volume Cost/High Volume Strength Surface Finish
10 10 10
9
8
7
2
3D Printing vs. Traditional Manufacturing
Cost Cost
Conventional Production Conventional Production
3D Printing 3D Printing
No. Of Pieces Complexity Of Pieces
Different 3D Printing Techniques
FDM SLA / DLP SLS SLM
PJP Binder jet LOM CLIP
What Can Be 3D Printed
Plastics
Jewelry Health
Metals
Care Compound
Research Mtrls Fashion
Ceramic
Personalized Items Dresses, materials,
adornments
Art
Resins Hobby/
Chocolate
Gifts Accessories
Paper Food
Sandstone
Unique toys, arte-
facts, sculptures
Three Phases of Development Leading to Rapid Prototyping
First Phase: Manual Prototyping
Geometric Modeling Prototyping
• First Phase: 2D Wireframe First Phase: Manual Prototyping
Started in mid-1960s • Traditional practice for many centuries
Few straight lines on display may be: • Prototyping as a skilled crafts is:
• circuit path on a PCB • traditional and manual
• plan view of a mechanical component • based on material of prototype
“Natural” drafting technique • “Natural” prototyping technique
Second Phase: 3D Curve and Second Phase: Soft or Virtual
Surface Modeling Prototyping
• Mid-1970s • Mid-1970s
• Increasing complexity • Increasing complexity
• Representing more information about precise shape, size and • Virtual prototype can be stressed, simulated and tested,
surface contour of parts with exact mechanical and other properties
Third Phase: Solid Modeling Third Phase: Rapid Prototyping
• Early 1980s • Mid-1980s
• Edges, surfaces and holes are knitted together to form a • Benefit of a hard prototype made in a very short
cohesive whole turnaround time is its main strong point (relies on CAD
• Computer can determine the inside of an object from the modeling)
outside. • Hard prototype can also be used for limited testing
• No longer ambiguous but exact • Prototype can also assist in the
manufacturing of the products
Industries Implementing 3D Printing
Jewelry Health Care Research Fashion
Personalized Items Guides, Prosthetics High precision parts Dresses, Ornaments
Art Hobby/ Gifts Accessories Food
Unique toys, Sculptures Personalized Gifts Custom fit shoes… Various food items
Case Study 1 – Personal Memento
Step 1 : Concept Design Step 2 : Part Creation
Step 4 : Finishing Step 3 : Assembly
Case Study 2 – Industrial Layout
Step 1 : Aerial Survey Step 2 : Topography
Step 4 : Finishing Step 3 : Elements Printing
Case Study 3 – Fiber Mould Batch Production
Step 1 : Concept Step 2 : 3D Design
Step 4 : Batch Production Step 3 : 3D Print
The Rapid Prototyping Wheel depicting
the four major aspects of RP
Results of the integration of RP technologies
Classification of Additive Manufacturing Technology
Materials for Additive Manufacturing Technology
Tooling
Applications
Seven sub-categories of software that are applicable to Additive Manufacturing, sorted
by the need into four main categories