Additive Manufacturing Page #1

Asha P B Dept. of Mechanical Engineering Global Academy of Technology

Module 2 :Additive Manufacturing Techniques:

Fusion Deposition Modelling: Process, Process parameter, Process
Selection for various applications. Introduction to Stereo Lithography,
LOM, SLS, SLM, Binder Jet technology.

Additive Manufacturing Application Domains: Aerospace, Electronics,

Health Care, Defence, Automotive, Construction, Food Processing,
Machine Tools

1.0 Selecting the suitable additive manufacturing (AM) process

Selecting the suitable additive manufacturing (AM) process depends on various

factors, such as the material, the complexity of the design, the required precision,
the volume of production, and the intended application.

1.1 Based on Material:

 Stereolithography (SLA) and Digital Light Processing (DLP) are suitable for resins
and thermosets.
 Selective Laser Sintering (SLS) and Selective Laser Melting (SLM) are suitable
for metals and some high-performance polymers.
 Fused Deposition Modeling (FDM) is suitable for thermoplastics.

1.2 Based on Complexity and Precision:

 Processes like SLA and DLP offer higher resolution than FDM for designs with fine details.
 SLS and SLM can produce complex geometries, including internal structures, making
them suitable for functional parts with precise specifications.

1.3 Based on Volume of Production:

 SLA, SLS, or SLM are more cost-effective for low-volume production due to their
ability to produce detailed parts without expensive tooling.
 FDM is more suitable for larger volumes due to its comparatively faster production rates.

1.4 Based on Applications:

 Aerospace Industry

o Selective laser melting (SLM) or electron beam melting (EBM) are commonly
used to Produce lightweight, high-strength components for aircraft and
spacecraft.
o GE Aviation uses SLM to create fuel nozzles for jet engines.

 Medical Field

o Selective Laser Sintering (SLS) or Stereolithography (SLA) is often preferred in

creating custom implants and prosthetics.
o In dental applications, SLA produces accurate and patient-specific
dental models or aligners.

o In orthopedics, SLS creates lightweight, custom-made implants tailored to the

patient's anatomy.

 Automotive Sector

o FDM, SLS, and SLM are used for prototyping, tooling, and end-use parts
production in the automotive sector.
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Asha P B Dept. of Mechanical Engineering Global Academy of Technology
o BMW uses fused deposition modeling (FDM) to prototype parts rapidly during
the vehicle design phase.
o Selective Laser Sintering (SLS) or Selective Laser Melting (SLM) for
producing functional prototypes.

 Consumer Goods and Design

o Stereolithography (SLA) or Digital Light Processing (DLP) are popular choices in

customization and small-scale production of consumer products due to their
ability to create high-detail, visually appealing prototypes.

 Engineering and Tooling

o Direct Metal Laser Sintering (DMLS) or Selective Laser Melting (SLM) are often used
to create complex and customized manufacturing tooling.
o DMLS is used to create intricate, high-strength tooling for composite part
production.

2.0 Fused Deposition Modelling

o FDM is an additive manufacturing process that creates three-dimensional
objects layer by layer.
o FDM was developed by Scott Crump in the late 1990s.
o FDM is one of the most widely used methods for producing prototypes,
models, and functional parts in various industries.
o FDM makes use of thermoplastics as raw materials that are fed in the form of
filaments.
o FDM can process a wide range of materials.

Fig: Fusion Deposition Modelling

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Asha P B Dept. of Mechanical Engineering Global Academy of Technology

2.1 FDM Process

1. Material Loading:

o The process begins with loading a spool of thermoplastic filament with a

diameter of 1.75 mm.
o Commonly used materials include Acrylonitrile Butadiene Styrene (ABS) and
Polylactic Acid (PLA).

2. Heating:

o The filament is then heated to its melting point within a nozzle.

o The nozzle temperature is precisely controlled.

3. Extrusion:

o The melted filament is extruded through a nozzle in a controlled manner.

o The nozzle moves along the X, Y, and Z axes based on the design specified in
the 3D model.

4. Layer-by-Layer Construction:

o The object is built layer by layer as the melted material is deposited onto
a platform or previous layers.
o The layers adhere to each other and gradually form the desired
three- dimensional object.

5. Cooling:

o Once a layer is deposited, it quickly cools and solidifies.

o This process is essential to ensure the structural integrity of the printed object.

6. Support Structures (if needed):

o In cases where the design includes overhangs, temporary support

structures can be added.
o These supports are typically made of the same material and removed after
the printing process.

Fused Deposition Modeling Advantages

FDM Technology Is Affordable

1. Flexible Design: Allows more complex designs.

2. Rapid Prototyping: Parts can be manufactured within hours.
3. Print on Demand: Saves space and costs as no need for large stock
inventories.
4. Strong and Lightweight Parts: Important for industries like automotive and
aerospace.
5. Fast Design and Production: Objects can be printed quickly depending on
complexity.
6. Minimising Waste: Only the material needed for the part is used, reducing
wastage.
7. Cost Effective: Saves time and costs by using a single step manufacturing
process.
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8. Ease of Access: More accessible with local service providers offering
outsourcing services.
9. Environmentally Friendly: Reduces material wastage and can improve fuel
efficiency with lightweight parts.
10. Advanced Healthcare: Capable of printing organs and advancing medical
technologies

Disadvantages

1. Limited Materials: Selection of plastics and metals is not exhaustive.

2. Restricted Build Size: Print chambers have small sizes, larger parts need to be
joined after printing.
3. Post Processing: Most parts require cleaning up and other post processing
methods.
4. Large Volumes: Cost per unit does not reduce significantly when scaled up for
mass production.
5. Part Structure: Layers can delaminate under stress due to the layer-by-layer
production process.
6. Reduction in Manufacturing Jobs: Automation could lead to job losses in
manufacturing sectors.
7. Design Inaccuracies: Some printers have lower tolerances, requiring post
processing to meet design specifications.
8. Copyright Issues: Increased risk of fake and counterfeit products due to
accessibility of the technology.
Applications
These are some of its applications:

 Models for dimensional and functional validation of product

 Parts with approved material for aeronautics
 Possibility of chromating ABS parts
 Manufacture of short series (low volume manufacturing) of pieces
 Manufacture of lower cost parts

Fused deposition modelling materials

The variety of materials accessible is one of FDM’s primary features. Commodity
thermoplastics such as PLA and ABS to engineering materials such as PA, TPU, and PETG.
For prototyping, there are high-performance thermoplastics such as PEEK and PEI during
the embodiment stages of the new product design.

3.0 Stereolithography (SLA)

 Stereolithography (SLA) is one of the earliest 3D printing processes.
 It was developed by Chuck Hull in the 1980s.
 The SLA process is called vat
photopolymerization, where a UV laser
selectively cures a liquid photopolymer
resin to create a solid 3D object.
 Stereolithography is known for producing
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Asha P B Dept. of Mechanical Engineering Global Academy of Technology
highly detailed and accurate parts with
smooth surfaces.

Preparation of 3D Model:
 The process begins with a 3D digital
model of the object that needs to be
printed.
 This model is typically created using computer-aided design (CAD) software.
Slicing the Model:
 Using slicing software, the 3D model is sliced into thin layers, typically ranging from
0.05 to 0.15 millimeters in thickness.
Preparation of the Build Platform:
 A platform is lowered into a tank filled with liquid photopolymer resin.
 The platform is positioned just above the surface of the resin.
Layer-by-Layer Building:
 Mirrors or galvanometers direct a UV laser to trace the object's cross-section
onto the surface of the liquid resin.
 The UV light selectively solidifies the resin in the pattern of the current layer.
Platform Movement:
 After a layer is solidified, the build platform is slightly lowered to allow for the
creation of the next layer.
 The process is repeated until the entire object is built layer by layer.
Curing and Support Structures:
 SLA printers use support structures to anchor overhanging parts of the object
during printing.
 These supports are also made from the same photopolymer resin.
Post-Curing:
 Once the printing process is complete, the object is not fully cured.
 It needs a post-curing step, exposing it to additional UV light to ensure
thorough curing and enhance its mechanical properties.
Support Removal and Finishing:
 After post-curing, the printed object is removed from the build platform, and
any support structures are detached.
 To achieve the desired surface quality, the object may undergo additional
finishing processes, such as sanding or polishing.
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Advantages

High-Quality Prints: This produces high-quality prints with smooth surfaces and intricate
details. This makes it ideal for creating prototypes, jewelry, and other detailed objects.

Faster Printing: This is faster than other 3D printing methods like FDM (Fused
Deposition Modeling). This is because it uses a laser to cure the resin, which is faster
than melting plastic filaments.

Wide Range of Materials: This can use a wide range of materials, including resins that are
flexible, rigid, or even transparent. This makes it versatile for a variety of applications.

Supports Complex Designs: This can support complex designs that are difficult to achieve
with other 3D printing methods. This is because of its ability to produce intricate details and
smooth surfaces.

Disadvantages

Expensive: SLA 3D printing is more expensive compared to other 3D printing methods. This
is because of the high cost of the liquid resin used in the process.

Limited Build Volume: SLA 3D printing has a limited build volume, which means that it
cannot create large objects. This makes it unsuitable for printing large prototypes or parts.

Messy Process: SLA 3D printing can be messy since it involves the use of liquid resin. This
can be difficult to clean up and can also be hazardous if not handled properly.

Post-Processing Required: SLA 3D prints require post-processing, which involves cleaning,

curing, and sanding the prints. This can be time-consuming and requires additional
equipment.

Applications of Stereolithography Process

The various uses of Stereilithography process are:

o Prototyping and product development

o Medical and dental models
o Custom jewelry and fashion accessories
o Architectural models
o Art and sculptures
o Rapid tooling and manufacturing aids
o Educational models
o Engineering and aerospace components
o Consumer electronics components

4.0 Laminated Object Manufacturing

 LOM is a 3D printing technology that creates three-dimensional objects by
layering and bonding sheets of material.
 The process is Developed by Helisys Inc.
 LOM is distinct from other 3D printing processes like Fused Deposition
Modeling (FDM) or Stereolithography (SLA) in its approach
 LOM is versatile in terms of materials. While paper is commonly used, other
materials like plastics, metals, or composites can also be employed.
 LOM is often used for creating prototypes, architectural models, and concept models
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Asha P B Dept. of Mechanical Engineering Global Academy of Technology

Laminated object manufacturing:

1. Foil supply. 2 Heated rollers. 3 Laser beam. 4. Scanning prism. 5 Laser unit. 6. Layers.
[Link] platform. 8 Waste.
1. Layered Material:
 The process begins with a stack of thin sheets of material, typically paper or
another flexible material like plastic or metal.
 Each sheet is coated with an adhesive on one side.
[Link] Cutting:
 A laser is used to cut the shape of the current layer into the material.
 The laser is controlled by a computer that follows the cross-section of the 3D model.
 The areas that will form the object are cut, leaving the unneeded portions intact.
3. Layer Bonding:
 After a layer is cut, heat is applied to the material to activate the adhesive.
 The cut layer is then pressed onto the layer below it, bonding them together.
 This process is repeated for each layer of the object.
4. Repeat and Build:
 Steps 2 and 3 are repeated layer by layer until the entire object is built.
 The unused portions of each layer remain as a support structure.
 This support structure can be easily removed once the object is complete.
5. Finishing:
 After the object is fully built, it must undergo post-processing.
 This includes sanding, painting, or applying additional coatings.

Advantages
 Ability to produce larger-scaled models
 Uses very inexpensive paper
 Fast and accurate
 Good handling strength
 Environmentally friendly Not health threatening

Disadvantages
 Need for decubing, which requires a lot of labor
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Asha P B Dept. of Mechanical Engineering Global Academy of Technology
 Can be a fire hazard
 finish, accuracy and stability of paper objects not as good as materials used with
other RP methods.

5.0 Selective Laser Sintering (SLS)

 SLS is an additive manufacturing (AM) technology that produces 3D

objects layer by layer using a laser to fuse powdered material.
 SLS uses materials like polymers, metals, ceramics, or composite
materials in powdered form.
 The powder material used needs to be evenly spread over the build platform.

Layering:
 The SLS machine spreads a thin layer of powdered material (typically around
0.1mm to 0.2mm thick) evenly across the build platform.

Laser Sintering:
 A high-powered CO2 laser selectively scans and fuses the powdered
material according to the digital model for that particular layer.
 The laser heats the powdered material just below its melting point, causing
particles to fuse.

Layer-by-Layer Building:
 Once a layer is sintered, the build platform lowers by the thickness of one
layer, and a new layer of powder is spread over the previous one.
 The laser then sinters the new layer, binding it to the previous layer.
 This process is repeated, layer by layer, until the entire object is formed.
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Asha P B Dept. of Mechanical Engineering Global Academy of Technology

Cooling and Solidification:

 As each layer is sintered, the surrounding powder helps dissipate heat, allowing
the newly fused material to cool and solidify.

Post-Processing:
 The build chamber cools down once the printing is finished and the excess
powder is removed.
 To achieve the desired finish, the printed object might undergo additional
processes like sanding, polishing, or surface treatments.

Advantages

 Mechanically resilient,
 no support structures are required,
 flexible components, v
 variety of materials,
 the most complex shapes possible,
 Thermally resilient.

Disadvantages:
 slightly rough surface,
 slow manufacturing process,
 only single-color models are possible.

Material: Different polyamide mixtures. (PA2200, PA12MD, etc.)

Applications:

 It has many applications, including:

 Medical devices: SLS can create custom prosthetics, orthotic devices, and surgical
instruments.
 Consumer products: SLS can create personalized jewelry, eyewear, and fashion items.
 Architectural models: SLS can create scale models of buildings and structures.
 Educational models: SLS can create models and teaching aids for engineering, biology,
and design.
 Research: SLS can be used for rapid prototyping of experimental designs and
components.
 Prototyping: SLS can be used for prototyping or robotic parts and gripping systems.
 Plastic parts: SLS can be used to produce small and medium series of 3D printed plastic
parts.
 Jigs and fixtures: SLS can be used to create jigs and fixtures.
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6.0 Selective Laser Melting (SLM)
 Selective Laser Melting (SLM) is an additive manufacturing process that uses a
high- powered laser to fuse metallic powders layer by
layer by melting.
 Metallic powders, such as aluminum, titanium,
stainless steel, or cobalt-chrome alloys, are
used in SLM.
 These powders need to be of high quality and
specifically engineered for the SLM process.
 In SLS, the powdered material is heated to a
temperature where particles fuse together
without fully melting. This fusion results in a
porous structure within the printed object.

Layering and Powder Deposition:

 The process starts by evenly spreading a thin layer of metallic powder material
(typically 20 to 50 micrometers thick) across the build platform.
 SLM fully melts the powdered material, resulting in a fully dense and solid
structure without the porosity seen in SLS-printed objects.

Laser Melting and Fusion:

 A high-powered laser scans the specific areas of the powdered layer
according to the digital model's cross-section.
 The laser selectively heats and melts the powdered material, causing it to fuse
and form a solid layer.
 The temperature is elevated to the melting point or slightly above to achieve fusion.

Layer-by-Layer Building:
 After a layer is melted and solidified, the build platform is lowered by the
thickness of one layer, and a new layer of metallic powder is uniformly
distributed.
 The laser then selectively melts the new layer, fusing it to the previous layer.
 This process is repeated, layer by layer, until the entire 3D object is formed.

Cooling and Solidification:

 As each layer is melted and fused, the surrounding powder helps dissipate
heat, allowing the newly formed metal to cool and solidify.

Post-Processing:
 The build chamber cools down once the printing is complete and excess metallic
powder is removed.
 To achieve the desired mechanical properties and surface quality, the printed
object might undergo further treatments like heat treatment, machining,
polishing, or surface finishing.

Applications

 functional parts for different assemblies and units;

 complex constructions with moving parts;
 molding elements for thermoplastic and lightweight material casting;
 prototypes;
 mold inserts for die casting;
 spare parts;
 patient-specific prostheses and implants;
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 dental appliances;
 jewelry models, and more.

Advantages

 No design limitations
 Reduced part weight
 Cost reduction
 Wide range of materials
 Reduced R&D cycle

Challenges in SLM Additive Manufacturing

These include

 Limited material selection compared to traditional methods,

 Post-processing requirements for surface finish and mechanical properties,

 Longer build times and higher costs for large and complex parts.

Binder Jetting
Step by Step

Powder material is spread over the build platform using a roller.

The print head deposits the binder adhesive on top of the powder where required.
The build platform is lowered by the model’s layer thickness.
Another layer of powder is spread over the previous layer. The object is formed where the
powder is bound to the liquid.
Unbound powder remains in position surrounding the object.
The process is repeated until the entire object has been made.

Materials:
Metals: Stainless steel
Polymers: ABS, PA, PC
Ceramics: Glass
All three types of materials can be used with the binder jetting process.
Advantages:
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Parts can be made with a range of different colours.
Uses a range of materials: metal, polymers and ceramics.
The process is generally faster than others.
The two material method allows for a large number of different binder-powder combinations and
various mechanical properties.

Disadvantages:
Not always suitable for structural parts, due to the use of binder material.
Additional post processing can add significant time to the overall process.

Applications
It has many applications, including:
 Metal parts: Binder jetting is good for making smaller metal parts like industrial components,
jewelry, filters, and golf club heads.

 Ceramics: Binder jetting can be used to make functional ceramic parts like silicon carbide nuclear
fuel structures, tungsten carbide wear components, and nozzles.

 Sand: Binder jetting is used to make foundry tooling for prototyping and production cast
parts. Infiltrated sand can also be used for vacuum- and thermoform tooling and end-use parts
like skate ramps.

 Prototypes: Binder jetting can be used to produce full-color prototypes.

 Aerospace parts: Binder jetting can be used to make aerospace parts.

 Casting patterns: Binder jetting can be used to make casting patterns.

 Cores and molds: Binder jetting can be used to make cores and molds.

Additive Manufacturing Application Domains:

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Food Industry
The food industry has embraced 3D printing technology to create new and
innovative food products. Overall, 3D printing allows for the creation of intricate shapes
and designs that would otherwise be difficult to achieve through traditional methods.
This has resulted in the development of novel and unique snacks, desserts, and even
complete meals that are both aesthetically pleasing and delicious. The technology also
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has the potential to produce complex geometrical shapes in a shorter period, making it
easier to produce healthier food products with precise control over the used ingredients.

Automotive Industry
The automotive industry is using 3D printing to create lighter and stronger parts for
cars, leading to improved fuel efficiency and performance. The technology also allows
for the rapid prototyping and testing of new designs, minimizing the time and expenses
required to launch a new product . Additionally, custom, and specialized parts are being
manufactured using 3D printing to maintain unique and vintage cars, offering owners a
more convenient option for vehicle preservation.

Additive Manufacturing is arguably the ideal production method for numerous

aerospace applications, particularly where light weighting and part consolidation are
high priorities. However, safety is the highest priority in this sector and it can take a long
time for new manufacturing methods to reach the shop floor, even when companies are
constantly searching for new ways to cut high material costs and reduce component
weight.
A branch of the aerospace industry that has successfully adopted AM technology is
the space sector. Here, Additive Manufacturing is being used to great advantage,
especially in the production of satellite and rocket parts that bring down the cost of
manufacturing and open up new applications that are not possible to produce by any
other method.
One such case is the aerospike rocket engine. When first conceived in the 1950s
and later tested by NASA in the 1980s and 90s, the project was put on hold, as effective
production was not possible. Today, this high-performance rocket engine is being
actively developed by Spain’s Pangea Aerospace and Aenium Engineering, with an AM
version built from a copper alloy, developed at NASA, now at the hot-fire testing stage.

Automotive applications for metal Additive Manufacturing

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The automotive industry is undergoing many changes, with regulations and demands for greater
sustainability and electrification driving innovation.

Metal Additive Manufacturing is a proven solution. However, the technology still has a way to go
when it comes to bridging the gap between prototyping and production in the automotive
industry. This is more often due to the cost of high-volume mass production, where there are
alternative, more established manufacturing routes. But competing with these mass-production
routes is not where the advantages of metal Additive Manufacturing stand out just yet.

Where it can shine in the automotive sector is with the shorter-run, performance applications.
One automaker pushing the boundaries of AM is the recently established Czinger Vehicles. The
company’s Czinger 21C hypercar incorporates over 350 AM components in the vehicle’s
structure, suspension, brake systems, drivetrain and more.

Although most automakers do have in-house metal Additive Manufacturing capabilities, these are
often only for prototype parts. Some, however, are now looking more seriously at how AM can be
incorporated in higher volumes. BMW, for example, has reported success where, together with
the twelve members of the Industrialisation and Digitalisation of Additive Manufacturing (IDAM)
consortium, a digitally connected, fully automated Additive Manufacturing line, specifically for
series production of automotive components, has been established at the BMW Group Additive
Manufacturing Campus in Oberschleissheim, Germany, with a further production line located at
GKN Powder Metallurgy’s facility in Bonn.

In this facility, a fully automated driverless transport system is used to carry mobile AM build
chambers between modules in the IDAM production lines. Further automation sees processed
metal powder delivered to workstations for preparation, and post-processing of the additively
manufactured components is conducted automatically at specially designed stations.

Other applications in the automotive sector include the replacement of parts used in vintage or
rare vehicles, where spare parts are increasingly hard to source. AM can also be used to repair
broken or damaged parts and replace the need for costly new tooling, which would be
uneconomical for such short runs.
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Question Bank

Cog.
Sl.N
Questions Leve
o.
l
With a neat sketch, briefly explain principle operation of Stereo lithography. State
1. L2
its applications.
Explain the principle operation of Selective laser sintering with neat sketch. List L2
2.
the advantages of it.
3. Sketch and explain Fused Deposition Modelling. Also add a note on FDM materials. L2

Outline the stages of the FDM process to develop accurate and compatible L2
4.
products for industrial applications.
With a detailed sketch explain the stages involved in the Selective Laser Melting L2
5.
process.
Create a detailed sketch illustrating the stages involved in Selective Laser Sintering L3
6.
techniques.
Evaluate the stages of working in Laminated Object Manufacturing techniques L3
7.
through a detailed sketch.
With a detailed sketch explain the stages involved in the Binder jet Technology L2
8.
process.
What factors should be considered when selecting the most appropriate additive L3
9.
manufacturing (AM) process for a given application?
How is additive manufacturing being utilized in the aerospace and automobile L2
10.
industry for lightweight and complex components?
What emerging application domains are leveraging additive manufacturing for L3
11.
innovative solutions? Explain any two in detail.