28-10-2020

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UME 505: MANUFACTURING TECHNOLOGY

UME 505: MANUFACTURING TECHNOLOGY

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Manufacturing processes can be broadly classified in four

major groups

a) SHAPING OR FORMING: Manufacturing a solid product

of definite size and shape from a given material.

b) JOINING PROCESS: Welding, brazing, soldering etc.

c) REMOVAL PROCESS: Machining (Traditional or Non-

traditional), Grinding etc.

d) REGENERATIVE MANUFACTURING: Production of solid

products in layer by layer from raw materials

UME 505: MANUFACTURING TECHNOLOGY

A prototype is defined as “An approximation of a product or system or

its components in some form for a definite purpose in its
implementation.”

The general purpose of the prototype contains three aspects namely:

• The form of prototype.
• The implementation of the prototype.
• The degree of approximation of the prototype.

Additive Manufacturing (AM) refers to new class of manufacturing

machines which quickly produce physical prototypes from 3D CAD models.

A picture is worth thousand

words but a physical prototype is
worth thousand pictures
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Machining is a subtractive process, beginning with a solid piece of stock.

The machinist must carefully remove material until the desired geometry is
achieved. For complex part geometries, this is an exhaustive, time
consuming and expensive process. Some parts are even too complex to
be machined.

UME 505: MANUFACTURING TECHNOLOGY

• AM process belong to the generative (or additive) production

processes unlike subtractive or forming processes such as
lathing, milling, grinding or coining etc. in which form is shaped
by material removal or plastic deformation.

• In all commercial AM processes, the part is fabricated by

deposition of layers contoured in a (x-y) plane two
dimensionally.

• The third dimension (z) results from single layers being stacked
up on top of each other, but not as a continuous z-coordinate.
Therefore, the prototypes are very exact on the x-y plane but
have stair-stepping effect in z-direction. If model is deposited
with very fine layers, i.e., smaller z-stepping, model looks like
original.
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Additive Manufacturing is classified into 4 principle steps.

• Create a CAD model of the design .
• Convert the CAD model to STL format .
• Slice the STL file into thin cross-sectional layers
• Construct the model one layer atop another

UME 505: MANUFACTURING TECHNOLOGY

Creation of Geometric Model

Tessellation

Slicing

Generation of Laser
Scanning Path

Part Fabrication

Post Processing

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FUSED DEPOSTION
MODELLING, MULTIJET
WIRE MODELLING, BALLISITC
PARTICAL MANUFACTURE

LAMINED OBJECT
MANUFACTURE, SOLID
SOLIDS FOIL FOIL POLYMERIZATION,
PAPER LAMINATION
TECHNOLOGY

SELECTIVE LASER
SINTERING, 3D PRINTING,
POWDER LASER ENGINEERED NET
SHAPING

STERIOLITHOGRAPHY,
ADDITIVE SOLID GROUND CURING,
MANUFACTURING LIQUID RESIN BEAM INTERFERENCE
SOLIDIFICATION

REACTIVE GAS PHASE

GASEOUS DEPOSITION
GAS
UME 505: MANUFACTURING TECHNOLOGY

ADDITIVE
MANUFACTURING

SOLIDIFICATION OF MELTING BY HEATING BY LASER FUSION OF FUSION BY

THE RESIN BY HEATING AND AND FUSION PARTICLES HEATING AND
ELECTROMAGNETIC SOLIDIFICATION WITH BINDER COMPRESSIVE
RADIATION FORCE

SELECTIVE LASER
STERIOLITHOGRAPHY, SINTERING, LASER 3D PRINTING
SOLID GROUND ENGINEERED NET
CURING, BEAM FUSED DEPOSITION SHAPING
INTERFERENCE LAMINATED OBJECT
MODELLING, MANUFACTURING,
SOLIDIFICATION MULTIJET SOLID FOIL
MODELLING, POLYMERIZATION,
BALLISTIC PARTICLE PAPER LAMINATION
MANUFACTURE TECHNOLOGY

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• In this process, photosensitive liquid resin

which forms a solid polymer when exposed
to ultraviolet light is used as a fundamental
concept. The process is called photo
polymerization.
• A SL machine consists of a vat of resin and a
UV Helium-Cadmium or Argon ion laser.
• The laser scans the first layer and platform is
then lowered equal to one slice thickness
and left for short time (dip-delay) so that
liquid polymer settles to a flat and even
surface and inhibit bubble formation.
• In SL systems, a blade spreads resin on the part as the blade traverses the vat.
This ensures smoother surface and reduced recoating time.
• Overhangs or cantilever walls need support structures as a green layer has
relatively low stability and strength.
• The green part is then post-cured in an UV oven after removing support
structures. UME 505: MANUFACTURING TECHNOLOGY

• Spooled filament of 0.070 inch nominal diameter are fed

into a liquefier head via computer driven rollers.
• The material in filament form is melted in a specially
designed head, which extrudes on the model.
• The liquefier head is machine controlled for movement in x-
y plane. A fixture-less build platform moves in z direction.
• The build material is heated slightly above (approximately
0.5° C) its melting temperature so that it solidifies within a
very short time (approximately 0.1 s) after extrusion and
cold-welds to the previous layer.
• The molten polymer is extruded out of the nozzle at the end
of the liquefier. Nozzle diameters between 0.01 inch to 0.05
inch can be used.
• A continuous wound spool of polymer is guided to the
liquefier head via a binding path before being fed into a pair
of counter rotating rollers.
• The polymer used in FDM process is ABS (Acetonitrile
Butadiene Styrene).
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• In SLS process, fine polymeric powder like polystyrene, polycarbonate or

polyamide etc. (20 to 100 micrometer diameter) is spread using a roller.
• Before starting laser scanning for sintering, the temperature of the entire
bed is raised just below its melting point by infrared heating in order to
minimize thermal distortion and facilitate fusion to the previous layer.
• A heat generating CO2 laser selectively scans the layer of powder to
fabricate the cross-sectional slice of CAD part.

UME 505: MANUFACTURING TECHNOLOGY

• The interaction of the laser beam with the powder elevates the
temperature to the point of melting, fusing the powder particles to form a
solid mass.
• The intensity of laser beam is modulated to melt the powder only in areas
defined by the part’s geometry.
• Surrounding powder remain a loose compact and serves as support.
• Once laser scanning cures a slice, bed is lowered by one layer thickness
and powder feed chamber is raised so that a covering of powder can be
spread evenly over the build area by counter rotating roller.
• The previous steps are repeated with each layer fusing to the layer below
it.

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Product Visualization

Design Presentation

Form, Fit and Function studies

Part Fabrication for Experimental
Setups

Functional Testing

Arts & Architecture

Production Tooling

Surgical Preplanning

UME 505: MANUFACTURING TECHNOLOGY

Medical Products made in AM

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CABLE FIXTURES HEARING AID SHELLS

WASHING MACHINE ROTOR

HIGH SPEED VENTILATION HOUSING FOR DRILLING

SYSTEM MACHINE

CAR SEAT

UME 505: MANUFACTURING TECHNOLOGY

• Reduced lead times (product to market).

• Reduced costs (labour, inspection and assembly).
• Reduce part count.
• Improved quality.
• Variety of materials.
• Fast build times.
• Create impossible and complex shapes.
• Reduced Waste.
• Reduced rejection rate.

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• Additive Manufacturing is a method in which the part is created

by a layered additive process.
• 3-D CAD model is sliced into very thin layers. Each layer
thickness varies from 0.10 mm to 0.20 mm.
• The AM machine constructs the part layer by layer until a solid
replica of the CAD model is generated.
• The advantages of this process is clear: development of physical
models can be accomplished in significantly less time as
compared to the machining process.
• Complexity of part is unimportant.

UME 505: MANUFACTURING TECHNOLOGY

• Chua, C.K., Leong, K.F. and Lim, C.S., Rapid Prototyping:

Principles and Applications (2nd Edition), World Scientific
Publishing Co. Pte. Ltd.
• Pham, D.T. and Dimov, S.S., Rapid Manufacturing: The
Technologies and Applications of Rapid Prototyping and Rapid
Tooling, Springer-Verlag London Limited 2001

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