Additive Manufacturing

- 3D Printing -
Borhen Louhichi

Sousse le 03-05-2019 1
Stereolithography Invention

Sousse le 03-05-2019 2
 Definition

Additive manufacturing (AM), a process

of joining materials to make objects from
3D model data, usually layer upon layer, as
opposed to subtractive manufacturing
methodologies.

ASTM F2792 - Standard Terminology for

Additive Manufacturing Technologies

Different names for AM

• 3D Printing
• Rapid Prototyping (& Manufacturing)
• (Solid) Free Form Fabrication
• Layer-based Manufacturing [1]
• Rapid Manufacturing
• Additive Manufacturing
[1] https://3dprintingindustry.com/3d-printing-basics-free-beginners-guide
Sousse le 03-05-2019 3
The Generic AM Process (Steps)

The Generic AM Process

Step 1: CAD
Step 2: Conversion to STL
Step 3: Transfer to AM Machine
and STL File Manipulation
Step 4: Machine Setup
Step 5: Build
Step 6: Removal
Step 7: Post-processing
Step 8: Application

Sousse le 03-05-2019 4
 The 7 AM methods (ASTM F42)

1. Photopolymerization: material is cured by light-activated polymerization.

2. Material Jetting: droplets of build material are jetted to form an object.
3. Powder bed fusion: Energy (typically a laser or electron beam) is used to
selectively fuse regions of a powder bed.
4. Binder Jetting: liquid bonding agent is jetted to join powder materials.
5. Material Extrusion: material is selectively dispensed through a nozzle and
solidifies
6. Sheet Lamination: Sheets are bonded to form an object.
7. Directed Energy Deposition: Focused thermal Energy is used to fuse
materials by melting as deposition occurs.

Sousse le 03-05-2019 5
 1. Photopolymerization

Photopolymerisation – Step by Step

The build platform is lowered from the top of

the resin vat downwards by the layer
thickness.
A UV light cures the resin layer by layer. The
platform continues to move downwards and
additional layers are built on top of the
previous.
Some machines use a blade which moves
between layers in order to provide a smooth
resin base to build the next layer on.
After completion, the vat is drained of resin
and the object removed [2].
The Vat polymerisation process uses Plastics and Polymers.

[2] https://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing/

Sousse le 03-05-2019 6
 2. Material Jetting

Material Jetting – Step by Step

The print head is positioned above build
platform.
Droplets of material are deposited from
the print head onto surface where
required, using either thermal or
piezoelectric method.
Droplets of material solidify and make
up the first layer.
Further layers are built up as before on
top of the previous.
Layers are allowed to cool and harden
or are cured by UV light. Post
processing includes removal of support
material [2].

The material jetting process uses polymers and plastics.

Polymers: Polypropylene, HDPE, PS, PMMA, PC, ABS, HIPS, EDP
Sousse le 03-05-2019 7
 3. Powder Bed Fusion

Powder Bed Fusion – Step by Step

A layer, typically 0.1mm thick of material
is spread over the build platform.
A laser fuses the first layer or first cross
section of the model.
A new layer of powder is spread across
the previous layer using a roller.
Further layers or cross sections are
fused and added.
The process repeats until the entire
model is created. Loose, unfused
powder is remains in position but is
removed during post processing [2].
The Powder bed fusion process uses any powder based materials, but common
metals and polymers used are:
SHS: Nylon DMLS, SLS, SLM: Stainless Steel, Titainium, Aluminium, Cobalt
Chrome, Steel EBM: titanum, Cobalt Chrome, ss, al and copper (Materials
Arcam, 2014).
Sousse le 03-05-2019 8
 4. Binder Jetting

Binder Jetting – Step by Step

Metals: Stainless steel
Polymers: ABS, PA, PC
Ceramics: Glass
All three types of materials can be used with the binder jetting process.
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 [2].

Sousse le 03-05-2019 9
 5. Material Extrusion

Material Extrusion – Step by Step

First layer is built as nozzle deposits
material where required onto the cross
sectional area of first object slice.
The following layers are added on top of
previous layers.
Layers are fused together upon deposition
as the material is in a melted state [2].

The Material Extrusion process uses polyers and plastics.

Polymers: ABS, Nylon, PC, PC, AB

Sousse le 03-05-2019 10
 6. Sheet Lamination

Sheet Lamination – Step by Step

The material is positioned in place on the
cutting bed.
The material is bonded in place, over the
previous layer, using the adhesive.
The required shape is then cut from the
layer, by laser or knife.
The next layer is added.
Steps two and three can be reversed and
alternatively, the material can be cut before
being positioned and bonded [2].

Effectively any sheet material capable of being rolled. Paper, plastic and some
sheet metals.
The most commonly used material is the paper.

Sousse le 03-05-2019 11
 7. Directed Energy Deposition

Direct Energy Deposition – Step by Step

A 4 or 5 axis arm with nozzle moves around
a fixed object.
Material is deposited from the nozzle onto
existing surfaces of the object.
Material is either provided in wire or powder
form.
Material is melted using a laser, electron
beam or plasma arc upon deposition.
Further material is added layer by layer and
solidifies, creating or repairing new material
features on the existing object [2].

The Electron Beam Melting process uses metals and not polymers or ceramics.
Metals: Cobalt Chrome, Titanium (EBM - Built Materials).

Sousse le 03-05-2019 12
The 7 AM methods (ASTM F42)

1 2

3 4

5 6

Sousse le 03-05-2019 13
FIELDS OF DEVELOPMENT AND INNOVATION

Sousse le 03-05-2019 14
FIELDS OF DEVELOPMENT AND INNOVATION

Aerospace Architecture

Automotive Jewellery

Art / Design / Sculpture

Sousse le 03-05-2019 15
Classes of Machines for Additive Manufacturing

Sousse le 03-05-2019 16
Simulation IdeaMaker

Sousse le 03-05-2019 17
Sousse le 03-05-2019 18