Additive Manufacturing - Module
1
Simplified for Easy Understanding
1. Introduction to Additive
Manufacturing
• Also known as 3D Printing or Rapid
Prototyping.
• • Creates objects layer-by-layer from CAD
data.
• • Opposite of Subtractive Manufacturing (like
CNC).
• • Emerging technology in aerospace, medical,
automotive industries.
2. AM vs Traditional Manufacturing
• AM: Adds material layer-by-layer.
• • Traditional: Removes material from a block.
• • AM is good for complex shapes and
prototyping.
• • Traditional is better for mass production.
3. Advantages of Additive
Manufacturing
• Design freedom – complex geometries
possible.
• • Reduced material waste.
• • Rapid prototyping – faster development.
• • Mass customization possible.
• • No tooling required.
4. Limitations of Additive
Manufacturing
• Slower than traditional methods for large
volumes.
• • Limited material selection.
• • Surface finish may be rough.
• • Expensive machines and post-processing
needed.
5. Generic Additive Manufacturing
Process
• 1. CAD Model Creation
• • 2. STL File Generation
• • 3. Slicing (Layering)
• • 4. Material Deposition Layer-by-Layer
• • 5. Post-processing (Cleaning, Curing)
6.1 Material Extrusion
• Filament is heated and extruded through a
nozzle.
• • Example: Fused Deposition Modeling (FDM).
• • Material: Thermoplastics like PLA, ABS.
6.2 Vat Photopolymerization
• Liquid resin cured by UV light.
• • Example: Stereolithography (SLA).
• • High precision and surface finish.
6.3 Powder Bed Fusion (PBF)
• Powder fused using laser or electron beam.
• • Examples: SLS, DMLS.
• • Materials: Polymers and Metals.
6.4 Binder Jetting
• Liquid binder glues powder particles.
• • Used for metals, ceramics, and sand models.
• • Requires post-processing like sintering.
6.5 Directed Energy Deposition
(DED)
• Focused thermal energy melts material as it's
deposited.
• • Used in metal repair and aerospace.
• • Material: Powder or wire.
6.6 Material Jetting
• Droplets of material are jetted and cured by
light.
• • Very high resolution and multi-material
capabilities.
6.7 Sheet Lamination
• Layers of sheet material bonded and cut.
• • Example: Laminated Object Manufacturing
(LOM).
• • Materials: Paper, metal, polymer sheets.
7. Applications of Additive
Manufacturing
• Aerospace: Lightweight complex parts.
• • Medical: Implants, dental models,
prosthetics.
• • Automotive: Prototypes and custom parts.
• • Consumer goods: Wearables, fashion.
• • Architecture, Art, Education.