Additive Manufacturing: Current Technology, Materials and Applications

Aditya Verma, Pulkit Dureja, Prajjwal, Raghav Bansal, Mandeep Dhanda and R.S Walia

Department of Production and Industrial Engineering, Punjab engineering College, Chandigarh,

India.

Abstract

Additive Manufacturing (AM) is a rapidly evolving technology transforming prototype

development into industrial production. Today AM has become a versatile and cost-effective
manufacturing method in many bio-medical, automobile, aerospace, electrical, household
appliances and toy making industries. It has gained widespread acceptance due to its ability to
create complex geometries with customizable material properties. Over past decades several new
techniques and processes for AM have popped out leading to lack of manufacturing guidelines and
standardization. The aim of this research paper is to collect and organize the vast knowledge
surrounding AM into a comprehensive paper. This paper also discusses the current state of various
material used for AM, challenges, uses and their applications. Overall, this paper gives an
overview of 3D printing (a branch of AM), including a survey on its benefits and drawbacks as a
benchmark for future research and development.

1. Introduction
3D printing comes under the branch of additive manufacturing (AM). It is a process that makes
3D objects of any shape when electronic data source is provided to it. Successive layers of
materials are layered one on top of other by computer controls [1]. The credits of 3D printing goes
to Charles hull who designed first ever 3D printer in 1984. 3D printing includes creation of 3D
CAD model data, conversion to STL file, file transfer to machine, machine setup, build prototypes,
part post processing, inception of the parts & finally delivery of the final finished part [2]. Different
processes and techniques are used in 3D printing. Processes which melt or soften the material to
produce the layers and the methods which cure liquid materials using different technologies.
Polymer materials and different bio-materials are used for different medical application based on
respective properties like ease of printing, biocompatible, morphologically mimicking living
tissue, nontoxicity etc. 3D printing brings forth increased productivity, flexibility and
customization according to user’s need. Lack of compatible material, high skilled worker and
insufficient research prevents 3D printing from becoming mainstream. Various 3D Printing
techniques like Stereo-lithography, Selective Laser Sintering and Fused Deposition Modelling are
employed to make various utilities [3]. Emergence of open-source communities in 3D printing has
helped in innovation which in turn has led to growth of the industry. These innovations are adopted
generally by proactive companies which can help them in price reduction and improving the
Overall efficiency of the manufacturing process. Presently there are different techniques of 3D
printing but each one has their own limitations which prevent them from becoming mainstream.
Lack of suitable material, cytoxicity and post processing difficulties make their adoption harder.
One thing is for sure that 3D printed dental utilities are more comfortable and efficient [ add
reference here].
This paper talk about general overview of Additive Manufacturing , its scope and various
applications. Various Materials and techniques of AM are briefly summarized in table along with
their advantages and disadvantages. The paper aims to provide basic understanding of AM in a
comprehensive and inclusive way.

2. Additive Manufacturing Techniques and Processes

The process of making a part by AM starts in Computer. Various designing software like
AutoCAD, Solidworks , Autodesk etc. are used to make design of the component. Then this file is
converted into STL format. Here the STL file is dissected into several layers of thickness
depending upon the requirement (for high surface finish more layers leading to thin thickness and
vice versa). Each layer is created via the selective deposition of material (and/or energy to fuse the
raw material) to form a printed primitive. Each layer is created via the selective deposition of
material (and/or energy to fuse the raw material) to form a printed primitive.
There are many types of 3D Printers that use various techniques to cater to specific
application and purpose. Different techniques of AM have different resolution and ability to make
parts [4]. Different techniques have their own merit and demerits. Various techniques have
different goal to build the part like somewhere strength of part (as in titanium implant by SLS) can
be the primary objective whereas somewhere accuracy may be more desirable. For example,
Extrusion AM systems typically have the largest layer thickness due to the large diameter of the
deposition nozzle. Alternatively, powder bed fusion and vat photopolymerization AM
technologies systems have much smaller layer thicknesses and smooth surface finish. ASTM
International has classified AM technologies into seven categories [5]:
(1) Material extrusion (2) powder bed fusion (3) vat photopolymerization
(4) Material jetting, (5) binder jetting, (6) sheet lamination
(7) Directed energy depositions
Details about each technique are listed in Table 1.

Table 1: Classification of various 3D printing techniques

Methods Techniques Used Materials Used Source of Advantages Disadvantages
Energy

Fused Deposition • Acrylonitrile Thermal • Complex • The size of the output

Modelling (FDM) Butadiene Energy parts can be product is limited to a very
styrene (ABS) reduced with small size.
• Polylactide good accuracy
Material (PLA) and with low • Raw material limitations
Extrusion thermoplastics cost
• No need for • FDM is a developing
special
tooling. process.
• As simple as
printing of
copy from
normal inkjet
printer.
Selective Laser Polyamides (PA), High • Uses • Post processing necessary.
Sintering (SLS) Polystyrenes (PS), Power materials like • Materials used for
Thermoplastic Laser titanium and processing is limited.
elastomers (TPE), Beam nylon.
• Does not
Polyaryletherketones
require any
(PAEK) support
Power Bed
Fusion materials.

Direct Metal Aluminium, stainless High • Create • Small build size.

Laser Sintering steel and titanium, as Power geometrically • Expensive process.
(DMLS) well as niche alloys Laser complex parts
like MONEL® Beam • Create strong
metal parts
K500 and Nickel
• Topology
Alloy 718. optimisation,
reduced
weight and
increased
strength
Electron Beam Titanium alloys, High • Rapid • Restricted part size.
Melting (EBM) cobalt chrome, steel energy production • Low accuracy
powders and nickel electron • Less need for • High material cost.
alloy 718 beam supports.
• Minimal
waste
Stereolithography Resins (standard, Ultraviolet • Fast • Fragile
(SLA) engineering, dental Radiation • Accurate • Expensive machinery
and medical, or • Works with Unsuitable for mass
castable resins) different production.
Vat Photo materials.
Polymerisation • Cost effective.
Sustainable
Digital Light Liqcreate resins Ultraviolet • Intricate and • Parts degrade under sun
Processing (DLP) radiation accurate • Parts susceptible to
or visible designs breaks or cracks
light • Faster and • Expensive costs of resins
more
economic than
SLA.
MultiJet Fusion Polyamide and • Fast build time • Rough surface quality
thermoplastic • Cost efficient • Lack of ceramic material
polyurethane • Parts are
strong and
virtually
 isotropic
• Manufacturing
Material Thermal of bigger parts.
Jetting Energy • Automated
Photo post
production
curing
process.
PolyJet ABS materials, bio • Objects with • Overexposure to UV
compatible PolyJet different lights can weaken the
photopolymer, levels of part.
simulated flexibility can • Time consuming
polypropylene
be produced. • Costly
• Versatile • Plumbing required for
• Multi removing support
coloured material.
objects
possible.
Indirect Inkjet Metals, sand, and Thermal • Very large • High cost of systems
Printing (Binder ceramics that come Energy size • No technical ceramics
Binder Jetting 3DP) in a granular form. capabilities support
• Very high • Increased competition
production from HP, GE, Desktop
speed. Metal
• Ability to
process a
wide range of
materials.
Laminated Object Polymer composites, Laser • Reduced • Inferior surface quality
Manufacturing ceramics, paper, Beam tooling and and dimensional accuracy
Sheet (LOM) metal filled tapes, manufacturing • Limitation in manufacturing of
Lamination metal rolls time complex shapes
• Versatile
• Low cost
• Excellent for
larger
structures
Direct Energy Laser Engineered Metals and alloys in Laser • Good granular • Post processing is
Deposition Net Shaping the form of powder Beam structure involved
(LENS) or wire, ceramics • Few materials • Part must be cut from
and polymers limitations build substrate
• Doesn’t • Rough surface finish
require • Low dimensional
secondary accuracy
firing
operation
Electron Beam • Clean process • Setup costs
Welding • High quality • Size limitations
and integrity • Complex technical
• Repeatable equipment
accuracy and
quality
control

From the above table it is clear different applications require different techniques of AM
depending upon the properties required. Material extrusion and vat polymerization is applied
where accuracy is preferred while Powder bed fusion or Direct energy deposition is used when
metallic components ae to be made with high strength. However, it is noteworthy that every
technique has major limitations like cost , post processing difficulties that is overall preventing
AM from becoming mainstream and suitable for mass manufacturing.
 3. Materials for Additive Manufacturing

Different materials possess different properties that makes them suitable for specific AM
processes. While metal powder is suitable for PBF or DED polymers are used for Extrusion and
polymerization.
Table 2: Commonly used Materials in Additive Manufacturing

Material Techniques in which Properties Applications

used

ABS Material Extrusion- • High Melting point(200*) Functional prototyping, concept

(Acrylonitrile (can with stand high heat) modelling, and production of
Fused deposition • Tensile strength about 4700psi tooling as well as some end use
butadiene styrene)
modelling (FDM)
parts.

Poly Lactic Acid Fused deposition • Has an impressive tensile Print plastic containers, medical
(PLA) modelling (FDM) strength of about 7250psi implants, and packaging materials.
• When exposed to high
temperatures, the durability
and strength of PLA will
severely weaken.
Carbon fibre Powder bed fusion • High specific stiffness Aerospace industry
reinforced strength
polymers • Good corrosion resistance
composite • Good fatigue performance

Glass fibres Powder bed fusion • High thermal conductivity It has great potential applications
reinforced • Relatively low coefficient of due to the cost effectiveness and
polymer thermal expansion high-performance.
composite

TI6AL4V Selective laser melting • High mechanical strength Automotive, aerospace,

(SLM), Direct metal • Low density medical/biomedical, chemical and
(Titanium Alloy)
laser sintering (DLMS), • Excellent corrosion resistance military applications
Binder jetting, sheet
lamination

Resins Stereolithography • High chemical resistance Highly useful in engineering and

(SLA), Digital Light • Material is rigid and delicate dental applications’
Processing (DLP)

ceramics Stereolithography • Strong Construction and building

(SLA) • Durable
dental and aerospace application
• Fire resistant
 Table 2 shows that polymer have high tensile strength making them suitable for high strength
applications. Resins with high chemical resistance are suitable for dentistry because of there non
toxicity. While ceramics make good material for construction because of strength and durance.
Metal additive manufacturing is predominantly used for prototyping or advanced applications in
the aerospace industry. It is also used in the biomedical, defence and automotive industries. The
process involves melting metallic feedstock (powder or wire) using laser or electron beam. The
melted material is transformed layer by layer to form a solid part. Polymers are the most widely
used materials in 3D printing industry due to their diversity and ease of adoption. They are found
in the form of thermoplastic filaments, reactive monomers, resin or powder. However, they lack
strength and functionality, and hence their use is often restricted to prototypes. 3D printed parts
which make use of ceramics find vast application in biomaterials and tissue engineering e.g.,
scaffolds for bones and teeth. Extrusion of ceramic paste or filament is also known extrusion free-
forming of ceramics (EFF). Parts produced by this method are usually cured by phase changing,
evaporation of water or solvent and UV or heat curing.

4. Advantages and Challenges of Additive Manufacturing

4.1 Advantages provided by AM

3D printing is called additive manufacturing because it created parts out of thin air by layer-by-
layer deposition of material. Since the material is added layer by layer it enables design and
manufacturing of complex and intricate geometries. There are no problems for need of fixture or
any other diverse tooling. Complexity of design is most easily and affordably manufactured by
AM. Printing can be stopped to put a foreign object inside the build which later will be fully
encapsulated by the part. The tolerance and allowances of AM methods are generally way less
than that of traditional manufacturing processes. It does on demand on location production can
reduce the cost involved in inventory and transportation thus saving both time and money.

4.2 Barriers and Challenges of AM

3D printing as of present is not accustomed for mass production. The cost for achieving economies
of scale via batch fabrication of standardized part geometry using AM is significantly larger than
via injection moulding techniques due to the discrepancy in cycle time. There is always a conflict
on what layer thickness must be there [6]. As thick layer produces parts with poor surface finish
while thin layer thin layer thickness increases the build time. Making heterogeneous product with
AM is presently difficult due to inter layer deficiencies and uncertainty. Products resulting from
state-of the- art AM systems suffer from anisotropic mechanical properties due to interlayer
bonding deficiencies. Furthermore, the environmental impact of 3D printing has not been properly
studies and more research needs to be carried out on it [7].

5. Application of AM in various Industries

5.1 Aerospace Industry

3D has made possible for the potential to manufacture light-weight , improved and complex
aircraft parts with minimised cost and high efficiency [8]. Reduction in parts in turn can lead to
fuel saving. 3D printing is extensively being employed in manufacturing spare parts of aircraft and
also sometimes engines. Nickel based alloy are preferred due to their high tensile strength and
corrosion resistance properties.

5.2 Automotive Industry

In the automotive industry, 3D Printing technique have made phenomena to bring new shines,
allowing for lighter and more complex structures in the fast time. Ford is the leader in the use of
3D printing technology also apply 3D printing technology to produce prototype and engine parts
while BMW uses 3D printing technology to produce hand-tools for automotive testing and
assembly [9]. 3D printing technology can reduce the wastage and consumption of the materials.
Moreover, 3D printing technology can reduce costs and time; therefore, it allows testing new
designs in a very fast time.

5.3 Electrical Industry

Different 3D printing technologies are being used for structural electronic devices like active
electronic materials, electrode and devices with mass customization and adaptive design by
embedding the conductors into 3D printed devices [10]. FDM is being used to mass produce
electrodes. 3D Printing is also being extensively being employed to produce circuits and
microchips to high degree of precision.

5.4 Medical Industry with focus on Dentistry

• Perhaps no industry has seen a revolutionised and drastic improvement in technology as

had the medical industry. Such has been the growth of 3D Printing in this sector that
printing skin bone and cartilage , replacement tissues , organ are all possible now [11] [12].
• 3D printing technology has achieved increased efficiency, accurate control of dropped size
and dose, high reproducibility and to produce dosage form with complex drug-release
profiles [13].
• 3D printing technology has helped in tissue regeneration. The replacement tissues
produced by 3D printing technology have interconnected pore network, biocompatible,
appropriate surface chemistry and has good mechanical properties [14].
• Prosthetics can be easily printed. 3D Printing also makes it possible to customize them
according to user’s preferences. [15]
• One area where 3D Printing has become mainstream is the dentistry. Applications such as
implants, aligners and dental bridges are produced by AM. Perhaps nowhere the benefit of
customisability is felt as in here. Each individual has different tooth structure hence can
have the dental equipment according to his own need. 3D Printed titanium implants are
highly porous thus can greatly improve Osseo integration [16]. 3D Printed aligners have
become the norm because of their ease and comfort [17]. 3D printing is now capable of bio
printing i.e., to print patient patient-tailored gingival tissue which are comfortable to
patient. These can mimic complex tissue structure within hydrogel [18].

6. Conclusion

The future of 3D Printing is bright. 3D printing machines could be used in our homes, various
businesses, and disaster sites and also in the outer space. However, there are some challenges that
must be solved such as the lack of 3D Printing expertise and technical maturity. There are
companies with narrow mind-set that still proceed with traditional approach of selling copyrights
instead of printing the actual parts. The scope of Future possibilities of 3D printing is vast. The
potential of metal-based 3D printing will allow for the creation of rare discontinued replacement
parts in a wide variety of applications. Repair shops could handle a much wider variety of clientele,
and online retailers may be able to print unique parts, providing more products through a just-in-
time inventory approach. More research needs to be carried out in suitable material for different
application to make them profitable at mass production. AM technologies can help in
customization of products by directly involving customers in the design stage. However, such
technologies are at a nascent stage due to the cumbersomeness associated with design and printing
software. Many of research still going on is fragmented hence significant problems are still arising
preventing 3D Printing from going mainstream. However, it is believed that the additive
manufacturing landscape will become more competitive in the coming future.

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