Additive Manufacturing Study Notes
1. Overview of Additive Manufacturing
Definition (ASTM): Process of joining materials to make objects from 3D model data, layer
by layer, unlike subtractive methods (machining).
Common Terms: Rapid Prototyping, Additive Manufacturing (AM), 3D Printing.
History: First appeared in 1980s as Rapid Prototyping. Charles Hull invented
Stereolithography (SLA) in 1983.
AM Value Chain: Material → System → Software → Application Design → Production.
Applications: Consumer, Automotive, Medical/Dental, Aerospace, Tools, Molds.
Advantages: Design freedom, speed, customization, tool-less, lightweight, sustainable.
Disadvantages: Accuracy limits, material limits, high cost, IP issues, safety risks.
2. Major AM Processes
2.1 Liquid-Based
Stereolithography (SLA): Laser cures liquid resin layer by layer. Requires supports, post-
curing. Very accurate, good finish, but brittle materials.
Digital Light Processing (DLP): Similar to SLA but uses conventional light source + DMD.
Faster, less waste, requires post-curing.
2.2 Powder-Based
Selective Laser Sintering (SLS): Laser sinters powdered material layer by layer. Powder bed
acts as support. Produces strong parts, but surface finish not as good as SLA.
Selective Laser Melting (SLM): Fully melts metal powders. Produces high-strength, dense
parts. Can process metals like steel, Ti, Al. Challenges: residual stress, cracks, porosity.
Electron Beam Melting (EBM): Uses electron beam in vacuum. Full melting, suited for
reactive metals (e.g., Ti). Produces dense, uniform parts.
Direct Metal Laser Sintering (DMLS): Similar to SLS but for alloys. Uses Yb-fiber laser. Builds
parts layer by layer.
2.3 Solid-Based
Fused Deposition Modeling (FDM): Most common extrusion-based. Filament heated and
deposited layer by layer. Pros: Wide material range, strong parts. Cons: Slow, less accurate.
Laminated Object Manufacturing (LOM): Layers of adhesive-coated sheets cut and bonded.
Resolution depends on sheet thickness.
3. Thermal Energy Based AM Processes
SLM: Uses CAD .stl file, sliced into thin layers. Parameters: beam density, spot size, speed,
powder size.
SLS: Laser fuses powder selectively. Produces solid structure. Cooling times long, risk of
porosity.
EBM: High-speed electrons in vacuum melt conductive powders. Produces fully dense parts
with uniform microstructure.
Directed Energy Deposition (DED): Melts material as it is deposited. Includes LENS, DLF,
DMD, WAAM, LMD. Used for repair or large builds.
FDM: Extrusion-based, filament melted and deposited. Requires supports. Strong parts but
slow process.
4. Melting & Sintering Processes
4.1 Selective Laser Melting (SLM)
Steps: Powder spread → laser melts → bed lowers → new layer spread → repeat. Produces
solid metal part.
Benefits: High density/strength, recyclable powders, complex shapes, wide metal range.
Challenges: Porosity, balling, cracks, residual stress.
Processing factors: Powder shape/size, laser power, scanning speed, layer thickness, scan
strategies, remelting.
4.2 Sintering
Powder particles (50–100 µm) heated, locally fused, and cooled.
Mechanisms:
• Solid-State Sintering: Fusion without melting. Driven by reduction of surface energy.
• Chemically Induced Sintering: Reaction forms binding by-products (common in ceramics).
• Partial Melting (Liquid Phase Sintering): Some particles melt and act as glue to bind
others.