ADDITIVE

MANUFCATURING
MANUFACTURING
Course code: KME 071

DEPARTMENT OF MECHANICAL ENGINEERING

MEERUT INSTITUTE OF ENGINEERING AND
TECHNOLOGY
 ABOUT COURSE
Additive Manufacturing (AM) is newly added course for the students of Mechanical Engineering. This course is
primarily focused on fundamental understanding of different additive manufacturing. The syllabus is oriented
to cover from basic understanding to classification of additive manufacturing, practical applications, and
advantages of this technology to develop the products. It covers almost all the direction of additive
manufacturing technologies including design aspects and software issues. In summary, the primary objective of
this course is understanding the:

∙ Basics of Additive manufacturing and Layer Manufacturing Processes

∙ Development of Additive Manufacturing (AM) Technology

∙ Types of Additive Manufacturing Processes

∙ Design & Software Issues in AM

∙ Material Design & Quality Aspects along with Applications of AM

 BOOKS AND REFERENCES
1. Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing,
by- Ian Gibson , DSavid W. Rosen , Brent Stucker, Springer.

2. Understanding Additive Manufacturing, by- Andreas Gebhardt, Hanser.

3. Additive Manufacturing, by- AmitBandyopadhyay, Susmita Bose, CRC Press.

4. Rapid Prototyping: Principles and Applications, by -Chee Kai Chua, Kah Fai Leong, Chu
Sing Lim.
 HISTORY OF ADDITIVE MANUFACTURING
• The term Rapid Prototyping (or RP) is used in a variety of industries to describe a process
for rapidly creating a system or part representation before final release or
commercialization.

• A recently formed Technical Committee within ASTM International agreed that

new terminology should be adopted. Recently adopted ASTM consensus
standards now use the term Additive Manufacturing.

• Additive Manufacturing” (AM) is a layer-based automated fabrication process for

making scaled 3-dimensional physical objects directly from 3D-CAD data without
using part-depending tools. It was originally called “3D Printing” and is still frequently
called that.
 FORMATIVE SUBTRACTIVE, AND ADDITIVE
Together with the well established
Formative
“Subtractive Manufacturing”, such as
milling or turning, and the “Formative
Manufacturing”, such as casting or forging,
Subtractive
Additive Manufacturing provides the third
supporting pillar of the entire
manufacturing technology.
• Additive
 DEFINTIONS FOR AM
• Additive Manufacturing” (AM) is a layer-based automated fabrication process for
making scaled 3-dimensional physical objects directly from 3D-CAD data without
using part-depending tools. It was originally called “3D Printing” and is still frequently called
that.

• AM is an automated manufacturing technique for fabricating three dimensional (3D) layered

artefacts directly from computer aided designs without the need of any tool, jig or fixture.

• Referred to in short as AM, the basic principle of this technology is that a model,
initially generated using a three-dimensional Computer Aided Design (3D CAD)
system, can be fabricated directly without the need for process planning.
 OFTEN TERMS USED
Additive Additive manufacturing (AM)
Additive layer manufacturing (ALM)
Additive Digital Manufacturing (DM)
Layer Layer based manufacturing
Layer oriented manufacturing
Layer manufacturing
Rapid Rapid technology, Rapid prototyping, Rapid tooling, Rapid manufacturing
Digital Digital fabrication
Digital mock up
• 3D Printing, 3D Modeling
• Direct manufacturing, Direct tooling
 PRINCIPLE OF LAYER BASED
TECHNOLOGY
• Generative Manufacturing
• “layer-based technology”,
“layer-oriented technology”, or even
“layered technology” .
• The principle of layer-based
technology is to compose a
3-dimensional physical object called
“part” from many layers of (mostly)
equal thickness.
• Each layer is contoured according to
the corresponding 3-dimensional data
set (see) and put on the top of the
preceding one.
AM PROCESS CHAIN
CAD image of a teacup with further images showing the effects of building
using
different layer thicknesses
 Generic AM Process
•
 Generic AM Process (STEPS)
• STEP 1: CAD
To describe the external geometry (software model, 3D CAD model)
Output must be a 3D solid
• STEP 2: Conversion to STL
AM machine accepts STL file format
describes external closed surfaces of 3D CAD,
• STEP 3:File transfer to AM machine
slicing calculation
STL file transferred to AM machine
Correct size, position, and orientation
• STEP 4:Machine setup
AM machine must be properly set up
Material constraint, energy source, layer thickness, timing
• STEP 5: Build
Superficial monitoring is required
running out of material, powder source
• STEP 6: Removal
Safety interlocks
Lower operating temperature
• STEP 7: Post Processing Additional cleaning up
Supporting features must be removed
• STEP 8: Application
Ready to use
Priming and Painting
DIFFERENCE BETWEEN AM AND CNC
 DIFFERENCE BETWEEN AM AND CNC
• Material
CNC: machinable foam and wax, but generally used for hard material
AM: Polymeric materials, waxes, and paper laminates, composite
• Speed
CNC: Part produced in multi stage (may take weeks)
AM: Part produced in single stage (few hours)
• Complexity
CNC: Undercuts, internal features can not be easily built
AM: higher complexity, Undercuts, internal features can easily
• Geometry built
CNC: Cylinders, cuboid, cones
AM: Undercuts, encloser, sharp corners (3D problem into 2D)
• Programming
CNC: Damage to the machine
AM: Part will not built
• Accuracy
 NOMENCLATURE OF AM MACHINE
1. If a machine is capable of fabricating parts, it is termed a “fabricator.”

2. If its capability is limited to fabricating prototypes, then it is called a “prototyper.”

3. “Printer/3D printer” is generally used for all AM machines. It is

prefixed with application genre, i.e. personal/professional.

4. In general, all AM machines can be put into three main categories

which are: fabber, office and shop-floor AM machines.
.
7. If an AM machine is used in an office, then it is called an “office AM
machine” and is characterized by minimal noise, odor, etc. Refilling
of the model/support material is undertaken by office staff and is
typically in cartridge form. Simple part handling, easy operation,
minimal maintenance, easy waste disposal, uncomplicated postprocessing, etc. are some key
features of this class of machines.
8. Its application is mainly for prototyping (primary or functional or
masters for secondary RP processes).

9. Sophisticated workspace, industrial ambience, skilled labor characterizes an industrial

shop-floor or simply shopfloor machine.

10. Their use is spread over manufacturing, prototyping, as well tooling.

11. The term “printer/modeller/fabricator/3D printer” is generally

used for these different AM machines as a general convention.

12. The price of fabbers is less than that of office AM modellers, which
in turn is less than that of shop-floor AM machines.

13. Operating skills required are minimal in case of fabbers. Anyone

professionally qualified in CAD software can work with office AM
machines. However, shop-floor machines require proper trained personnel.
NOMENCLATURE OF AM MACHINE
 TYPES OF AM TECHNIQUE
• AM processes based upon application levels. (Direct and Indirect)
• AM processes based upon type of modeller/raw material used. (Mettalic/Nonmettalic)
• AM processes based upon the physical state of raw material utilized. (Solid, liquid, powder)
• Based upon data transfer mechanism from stereolithography (STL) data format to the modeller.
• Based upon the working principle or underlying technique (resin polymerization, material extrusion)
• Basis of energy source used during the process. (binder, laser, plasma, beam of electron)
• AM on basis of raw material used. (Plastic, ceramic, powder, resin)
• Basis of material delivery system utilized. (Powder bed and Powder feed)
• VAT photopolymerization (VP), material extrusion (ME), binder jetting (BJ), material jetting (MJ), sheet
lamination (SL), powder bed fusion (PBF) and directed energy deposition (DED).
 PROTOTYPING, TOOLING, MANUFACTURING
• Direct AM process
• Indirect AM process

• All AM processes are called “direct processes” in order to indicate that the
digital
process model is directly converted into a physical object.

• Indirect Process do not apply the principle of layer manufacturing and

consequently they are not AM processes. Actually indirect processes are
copying techniques.

• Indirect AM parts can be regarded as master models and then used for
subsequent copying or reproduction processes.
Direct Prototyping/Rapid prototyping
Solid imaging or concept modeling
• The parts resemble a three dimensional picture or a statue.
• Show and tell models
Functional Prototyping, is applied to allow checking and verifying one or more
isolated functions of the later product or to make the production decision even
though the model cannot be used as a final part
 DIRECT MANUFACTURING/ RM

• The application level “Rapid Manufacturing” summarizes all processes that

deliver final products or final parts that need to be assembled to become a
product.
 DIRECT TOOLING
• Tooling encompasses AM applications
based on fabricating cores, cavities, inserts
for tools, dies and molds, etc.
 PROTOTYPE TOOLING
• If just a few parts are needed or details are changed frequently, a temporary
mold made from substitute material is typically sufficient.
INDIRECT PROTOTYPING
• Indirect prototyping is applied to improve the AM part’s properties in order to fulfill the
applicator’s requirements, if the AM part is not capable to do so. If, for example, a flexible
part is needed but due to material restrictions it cannot be built directly by AM process.
 INDIRECT TOOLING
• Indirect tooling is based on the same copying procedures as all indirect processes. It
is not the goal to obtain a final part, but a tool that provides the basis For a small or
medium size batch production of final (or series) parts or products.
INDIRECT MANUFCATURING
• Indirect manufacturing is based on AM masters as well. The goal is to obtain final
(or series) parts with properties equal to traditionally manufactured (non-AM)
products. Consequently, indirect manufacturing belongs to the application level
“Manufacturing”
LAYER MANUFCATURING PROCESSES
LAYER MANUFACTURING PROCESSES
Continue….
 Polymerization
The selective solidification of liquid monomeric resin (of the epoxy-, acrylate, or
vinyl ether type) by ultraviolet radiation is called (photo)-polymerization.

Laser-Stereolithography (SL)
• Oldest and detailed Process

• Part is obtained with good surface

• Initiated by a UV-laser
beam, the polymerization turns the liquid
into a solid, leaving a scaled solid layer.

• Platform goes down and process

continues until the object is formed

• Cleaning of the build part is required

 Polymer Printing-Jetting
• If the curable build material is applied by
print heads, the process is called polymer
printing or polymer jetting.

• Build material is directly applied to the

build platform through a multi-nozzle
piezo-electric print head.

• The solidification is done simultaneously

by a twin light curtain created by UV
LAMPS.

• Adjacent layers are processed

by moving the platform in the z-direction.

• The process continues layer by layer until

 Digital Light Processing

• Works with a commercial DLP

projector as UV light source.

• It projects the complete contour of a

cross-section of the actual layer and
initiates the solidification

• Projector is mounted into the lower part

of the machine body

• After solidification , the platform is raised

by the amount of one layer thickness

• Designed for small parts.

 Micro Stereolithography

• Make parts in the micro-millimeter and even in the sub-micro-millimeter range

 Sintering and Melting

• The selective melting and re-solidification of thermoplastic powders is called

laser sintering (also, depending on the manufacturer: selective laser sintering),
laser fusing or laser melting. If an electron beam is used instead of a laser the
process is called electron beam melting (EBM).

• Sintering processes in general do require neither bases to build the parts on nor
supports to link the parts to the bases, because the loose powder surrounds and
stabilizes the part during the build.
 Laser sintering-Selective laser sintering
• Machine consists of a build chamber, piston
and a laser scanner unit on top.

• Chamber is completely flooded by shielding

gas to prevent oxidation

• The top of the powder bed defines the build

area

• The laser beam is scanned to define a 2D

slice of object within layer.

• Molten layer then solidified the piston is

lowered to fill the space on top of powder

• Process continues until the full part is

formed
 Laser sintering-Selective laser melting
(SLM)

• Laser melting basically is a laser sintering process as described earlier. It was

developed in particular to process metal parts that need to be very (> 99%)
dense.

• The laser melts the material completely. Therefore, it produces a local

(selective) melt pool that results in a fully dense part after re-solidification.
 Electron Beam melting

• Local melting of the material can be

achieved by and electron beam

• A focused electron beam is scanned to

define a 2D slice of the object within a layer

• Can be used only for conductive materials

• Process is very fast

• Stress and distortion is reduced

 Layer Laminate manufacturing

• The cutting of contours out of prefabricated foils or sheets of even layer

thickness according to the sliced 3D CAD file and the subsequent
bonding on the top of the preceding layer is called layer laminate
manufacturing, LLM.

• The foils or sheets can be made of paper, plastics, metal, or ceramics. A

laser, a knife, or a milling machine can be used as a cutting device.

• The bonding of adjacent layers is done by glue, ultrasonic, soldering, or

diffusion welding.
 Laminated Object manufacturing
• The build material is coiled paper

• Down face is coated with glue/thermally

activated resin which is activated by
heat

• Bonding and Lamination of stacking

layer is achieved by heating and
compression by a heater roller

• When the heated roller passes over the

stacked sheets, the coating melts and
forms bond

• A laser does the cutting of the contour.

 Extrusion-Fused layer modelling

• Layer by Layer deposition of pastry strings is called fused layer modelling

.
• Process works with thermo-plastics

• Colored parts can be obtained

 Fused deposition modelling (FDM)
• Build Material continuously fed to the
extrusion head

• The material is partly molten in the

extrusion head by electrical heated
system and extruded through a nozzle

• After the deposition, the pastry strings

solidifies by the heat transfer into the
preceding layer

• The platform is lowered

• Process repeats until the part is

completed.
 Powder Binder Bonding-3D Printing (Drop on Powder Process)
• The layer-by-layer bonding of powder
particles by selectively injecting a liquid
binder into the top area of a powder bed is
called “Three Dimensional Printing – 3DP”.

• 3D Printing-Z Corporation

• 3D Printing- Protometal

• 3D Printing -Voxeljet
 Aerosolprinting
• A very interesting process with a high potential is called aerosolprinting.

• A stream of very fine droplets (aerolsols) is generated, loaded with ultra fine particles with
diameters in the nm range, and guided to the surface of a substrate.

• The liquid phase is vaporized, leaving the particles in place. The particles may consist of any
kind of functional inks, metals, ceramics, plastics, or even living cells.

• Depending on the kind of material, a post treatment by laser may be needed.

• Aerosolprinting is a very promising process for electronic devices as well as for tissue
engineering. As it is currently suitable only for 2½ D surface texturing and objects (at least
now) and not for real 3D parts, some do not regard it a real AM process.
 Bioplotter

• The 3D Bioplotter allows to process a wide variety of materials from plastics, such as
polyurethane or silicone, to bone materials such as hydroxyapatite, and drugs such as PCL
(polycaprolactone3) or materials such as collagen or fibrin for organ printing or soft tissue
fabrication.

• Up to five materials can be processed using either a heated or a cooled dispenser unit that is
operated by a 3-axis plotter.

• Depending on the material, the system uses different hardening processes such as
precipitation, phase transition (liquid to solid), or two-component reaction. Some materials
need post processing such as sintering.
 BENIFITS OF AM TECHNIQUE
• Highly customized parts can be made easily by the AM route.
• Operator intervention work is greatly reduced to a supervisory level.
• Set-up/machine preparation time in case of AM processes is appreciably less
• Noise free
• Can be operated from the comfort of home or office
• Lesser time for products to reach markets for customer end use
• Reduced material wastage owing to non-occurrence of mistakes
• Wide range of materials (polymers, metals, ceramics)
• Green manufacturing, clean, minimal waste
• Parts with complex and intricate geometries can be obtained at esser costs
• Tools, molds or punches not required.
 LIMITATIONS OF AM TECHNIQUE
• Part size
• Production series (Small production series)
• Material Properties: Parts made by additive manufacturing tend to show anisotropy in
the Z axis (construction direction).
• The densities of 99.9% can be reached, there can be some residual internal
porosities.
• Mechanical properties are usually superior to cast parts but in general inferior to
wrought parts.