Presented by

Dr. Biswanath Doloi

Professor & Ex-Head
Production Engineering Department
Jadavpur University
Email:bdoloionline@rediffmail.com
 Man Material

Method Production Machine

Money
Basic Manufacturing Concepts
MOVE REMOVE ADD and JOINING
MATERIAL
Introduction to Additive
Manufacturing
 Additive Manufacturing (AM) is a method in which
the part is created by a layer additive process
 Using a specialized software, a 3D CAD model is
generated and sliced into very thin layers or cross-
sections
 AM machine constructs the part layer by layer until a
solid replica of the CAD model is generated
 Bottom up approach
AM also known as
 Generative Manufacturing Processes
 Desktop Manufacturing
 Layered Manufacturing
 CAD Oriented Manufacturing
 Rapid Prototyping
 Solid Free forming
 3D Printing
Basic principles of RP
 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. Therefore, the
prototypes have stair-stepping effect in z-direction
Purpose of RP
 A prototype is an original full scale, and usually working
model of a new product or new version of an existing
product
 Prototype is needed as/for
 Concept models
 Functional or semi functional components
 Design analysis
 Design for manufacturing
 Master patterns
 Production tooling (pattern/mould making)
 Surgical planning for implant
Classification of AM/RP
Supply /Input build materials phase

Liquid Powder Solid

Stereo Laminated object

Selective laser
lithography(SLA) manufacturing(LOM)
sintering(SLS)

Solid ground 3 dimensional Fused Deposition

curing(SGC) printing(3DP) Modelling(FDM)

Rapid Freezing Laser Engineered

(RF) Net Shaping(LENS)
List of RP Techniques with build
materials
Popular AM method for Metal Parts

 Selective Laser Melting(SLM)

 Electron Beam Melting (EBM)
 Laser Engineering Net Shaping (LENS)
 Wire Arc Additive Manufacturing (WAAM)
 Stereo lithography Apparatus (SLA)

• Manufactured by 3D Systems
• Invented by Charles W. Hull
• The first commercial RP
system
• Use photo-curable liquid
resins
• Use UV laser
STEREOLITHOGRAPHY (SLA)
Strength and Weakness
Advantages
 Good surface finish;
 Complex geometry, easily obtained; and
 Generally, there is a good accuracy of the geometry.
Disadvantages
 Models need support structures that must be removed
as a finishing operation;
 Parts can warp, especially with acrylate resins; and
 Resins are hazardous and need careful handling.
 Applications of SLA
 Models for conceptualization, packaging, and presentation
 Prototypes for design, analysis, verification and functional
testing
 Parts for prototype tooling and low volume production
tooling
 Patterns for investment casting, sand casting and molding
 Tools for fixture and tooling design
Applications
 SOLID GROUND CURING
 Manufacture by Cubital
 Use Curable resin
 Use Glass mask
 Use UV light
SOLID GROUND CURING PROCESS

Mask Model
Generation Making
 Principle of SGC
 Parts are built layer by layer
 A liquid photopolymer solidifies when exposed to UV light
 Mask is used to control solidified areas
 Wax is used for support
 Layer thickness is controlled by milling process
 Multiple parts can be fabricated simultaneously
Strength and Weaknesses of SGC
Strengths
• Post-curing is not required
• No support is needed
• Appropriate for multiple parts fabrication
• Smooth surface
• Minimum shrinkage effect
Weaknesses
• Expensive
• Difficult to remove wax for complicated shape
• Excess Waste
 Selective Laser Sintering (SLS)

 Developed by DTM
 Currently manufacture by 3D systems
 Use bed of powder
 Selectively use CO2 laser to sinter powder
 Can be used with various
types of materials
SELECTIVE LASER SINTERING
Strength and weakness
Advantages
 No post-curing of the parts is needed, unless they are ceramic;
 Parts can often be built without additional support structures;
and
 Parts in a range of materials can be obtained directly.
Disadvantages
 Surfaces of the parts are porous, and surface finish can be poor;
 Process machines can take a long time to heat up and cool
down;
 Investment casting requires the surface of master parts to be
sealed; and
 Parts can warp significantly.
Applications
RAPID TOOL
 Rapid Steel 1.0
 Rapid Steel 1.0 powder is made up of low carbon steel particles with a mean dia
of 55 micron. The partcles are coated with a thermoplastic binder. Three main
stages are:
1. Green Part Manufacture (SLS Processing): Tooling inserts in the green stages
are built layer be layer through fusion of the binder.
2. Cross linking: During the low temperature furnace cycle, the green part is
infiltrated with an aqueous acrylic emulsion and dried in an oven at about 60
degree C.
3. Furnace Processing: In this stage, the green part is converted into fully dense
metal part by infiltration with molten copper. To remove oxides from steel surface,
a mixture of hydrogen and nitrogen is used during furnace cycle. Between 350 and
450 degree the polymer evaporates.
4. Then the temperature is increased to 1000 degree C to allow sintering of
steel powder. Finally the part is heated upto 1200 degree C where copper
infiltration occurs driven by capillary action. The rapid steel 1.0 parts consists of
60% steel and 40% copper.
RAPID STEEL 2.0
 The base metal has been changed from carbon steel to
316 stainless steel
 Bronze has replaced copper as the infiltrate
 The thermoplastic binder has been substituted by a
thermoset binder.
 The rapid Steel 2.0 parts are made up of 53 % stainless
steel and 47 % bronze.
 The stainless steel increase the mould wear resistance
and bronze gives better friction characteristics.
 Selective Laser
Melting (SLM)

2/8/2023
Schematic representation
of SLM
 SLM
 The additive manufacturing technology.

 SLM make it possibility to metal components layer by layer according to a 3D-

CAD models.

 Complex geometrics with out need of pre-production tools.

 Melts the material on the powder bed layer by layer.

2/8/2023
 SLM
 Alloys of Titanium, cobalt chrome, aluminum can be fabricated.

 No compromise in accuracy.

 No need of any auxiliary holding devices – Melting on powder bed.

 Completely melts the powder instead of fusing granules.

 Obtains mechanical properties similar to conventional manufacturing.

2/8/2023
 Parameters that effect the SLM

 Atmosphere
 Temperature
 Powder
 Laser power & thickness

2/8/2023
 Particle size of
Powder

The particles should be spherical for free- flowing on the bed

of SLM machine
The particle is in between 20µm and 80µm

2/8/2023
 Applications

Bio-medical Automotive Building And

Modeling

2/8/2023
ELECTRON BEAM MELTING (EBM)

Arcam AB, a Swedish technology development

company, founded in 1997, developped the Electron
Beam Melting (EBM) technique for the production of
solid metal parts directly from metal powder based on
a 3D CAD model.
 Arcam EBM, is widely used model, which uses H13
tool steel material with an operating temperature of
more than 1000°C is required to rapid prototype parts.
Process of EBM

 1. The part to be produced is first designed in a 3D CAD program.The model is then

sliced into thin layers, approximately a tenth of a millimeter thick.
 2. An equally thin layer of powder is scraped onto a vertically adjustable surface. The
first layer’s geometry is then created through the layer of powder melting together at
those points directed from the CAD file with a computer- controlled electron beam.
 3. Thereafter, the building surface is lowered and the next layer of powder is placed
on top of the previous layer. The procedure is then repeated so that the object from
the CAD model is shaped layer by layer until a finished metal part is completed.
Principle of EBM
 The EBM process is based on the following two principles;
1. Parts are built up when an electron beam is fired at the
metal powder.
 The computer controlled electron beam in vacuum melts
the layer of powder precisely as indicated by the CAD
model with the gain of the electrons’ kinetic energy.
 The building of the part is accomplished layer by layer. A
layer is added once the previous layer has melted.
 In this way, the solid details are built up of thin metal
slices melted together.
Fig. : Electron Beam Melting
Application of EBM
 The EBM process is used to manufacture H13 tool steel
injection and compression molding tools, functional
prototypes and components in small batches.
 EBM is an innovative technology for manufacturing
orthopedic implants, automobile and aerospace
applications.
 Examples of such applications are:
Complex lattice/framework structures for lightweight design
 Internal cavities for lightweight design, weight distribution
optimization and flow control
 Optimization of material and stress distribution
 Conformal cooling channels
 The technology is used by teams within the car racing
industry for fabrication of high performance parts and
prototypes.
 Fabrication of custom designed orthopedic implants
can benefit from efficient freeform fabrication in
metals such as commercially pure and alloyed
titanium.
 There is a future for customized Knee- and Hip-
implants that will provide better fitting and longer
lasting prostheses and most areas of orthopedic
implant surgery can benefit from customized
implants.
 Laser Engineered Net Shaping (LENS)

 Developed by Sandia National Lab

 Manufactured by Optomec
 Use metal powder
 Use laser
 Can be used for repairing parts
 LENS Process
 Deposit heads supply powder
to the focal point of a high-
powered laser beam
 The powder is welded onto the
build substrate or previous layer
 The nozzle is moved to create
the contour perimeter and to
form a solid cross section
 Powder is deposited along with
the laser beam to form a bead
 A bead is controlled to form a solid.
 Applications of LENS
 Build mold and die inserts
 Producing Titanium parts
 Repairing parts
 3D Printing
 Developed at MIT
 Manufactured by Z Corp
 Use binding agent instead of laser beam
 Use powder materials
3 DIMENSIONAL PRINTING
Principle of 3D Printing

 A part is built layer-by-layer

 Idea comes from printing technology
 The method is very similar to SLS,
except that glue is used as a binder
instead of laser beam
Applications
LAMINATED OBJECT MANUFACTURING
Applications
FUSED DEPOSITION MODELING
Applications
 Presentation on
Wire Arc Additive Manufacturing (WAAM)
Wire Arc Additive Manufacturing
 WAAM is a variation of a Direct Energy Deposition (DED)
technology and uses an arc welding process to 3D print metal parts.

 Unlike the more common metal powder AM processes, WAAM

works by melting metal wire using an electric arc as the heat source.

 The process is controlled by a robotic arm and the shape is built

upon a substrate material (a base plate).

 The wire, when melted, is extruded in the form of beads on the

substrate. As the beads stick together, they create a layer of metal
material. The process is then repeated, layer by layer until the metal
part is completed.
Fig.: Schematic Representation of WAAAM
Fig.: Schematic Representation of WAAAM setup
Fig.: Schematic Representation of WAAAM
Figure : Automated Planning Sequence for WAAM.
WAAM equipment
 The potential range of WAAM systems is vast, but most
fall into one of two types: robotic or machine tool-based.
At the time of writing, some commercial machine tool
and robotic WAAM systems are available, these are
leading the market for integrated systems and include
some very capable manipulation systems and
CAD/CAM software.
 However, almost any three-axis manipulator or robot
arm and an arc welding power source can be combined
to make an entry level WAAM system.
 Similarly, there are different types of power source
available and to some extent the material in use will
drive the arc deposition process selected.
 For example, titanium alloys are usually deposited with
more stable TIG or plasma transferred arc, whilst most
other materials are deposited with MIG equipment.
Fig.: WAAM Set up
WAAM-based process variables
and control
 WAAM is not a simple process to use. Whilst the main controllable
variables are the same as robotic welding, AM is a different process. All
the process variables combine to produce deposit bead geometry, and it is
manipulation of this bead that results in the desired component shape.
Unfortunately and unlike welding, bead geometry is affected by more than
just the deposition parameters; the residual heat as the part is built results
in a continuously changing thermal field that must be accounted for if a
deposited layer is to be accurate and free from defects.
 As parts become more complex, the programmed path of each layer
becomes significantly more so. It is rarely possible to strike an electric arc
at the beginning of a layer and extinguish it at the end. Most layers consist
of several ‘sub-shapes’ which are programmed and deposited separately
but joined together.
 Although offline programming software for WAAM is becoming
available, the success of the process can be reliant upon the skill of the
operator. Although the degree of software capability is developing rapidly,
until the ability to break a component down into sub-shapes, decide the
order in which they are to be built, consider thermal field, residual stress
and distortion, assign appropriate deposition parameters and compile a part
programme is completely automated.
Build Materials:
 WAAM can work with a wide range of metals,
provided they are in wire form. This list includes
stainless steel, nickel-based alloys, titanium
alloys and aluminium alloys. Any metal that can
be welded can also be used with WAAM.
SOFTWARE
Autodesk’s software products PowerShape and PowerMill are used for
creating CAD and CAM files. PowerShape is used for the (re)design of
components for WAAM. PowerMill is used for toolpath planning and
simulation. The toolpath that is made with PowerMill can be uploaded
directly to the MaxQ app using a web browser, from where production is
initiated.
The advantages of Wire Arc
Additive Manufacturing
 The ability to 3D print large metal parts: WAAM is particularly suited
to manufacture large-scale metal parts. This is in contrast to Powder Bed
Fusion (PBF) metal AM technologies, which typically produce smaller,
high-definition components.
 Cheaper process and materials : In terms of material costs, the welding
wire used in the WAAM printing process is significantly less expensive
than the metal powder used in metal PBF.
 High-quality parts : Parts produced with WAAM are particularly notable
for their high density and strong mechanical properties, which are
comparable to parts manufactured with traditional manufacturing
methods. As the wire feedstock is a 100 per cent dense input material, there
is negligible porosity induced in the fabrication process, leading to a very
dense final part.
 It’s suitable for repair operations:- WAAM is also a good option for
repair and maintenance operations for specific components like turbine
blades, as well as also moulds and dies.
Limitations of WAAM
 Residual stresses and distortions: One challenge associated with
WAAM is heat management. The printing process involves high
temperatures, causing the build-up of residual stress .As residual stress
can often lead to deformations in a component, cooling must be factored
into the process.
 Some materials require shielding :When using certain materials, like
titanium, shielding is necessary to create an inert atmosphere to ensure the
right building conditions.This means that the process has to take place in
an inert gas chamber.
 Low resolution : WAAM typically produces near-net-shape parts with a
poor surface finish. The surface of a part therefore needs to be finished via
machining.
 Precision: Whilst the early applications of WAAM included the use of
multi-axes robots, the positioning accuracy falls well short of that
available with specialist computer numerical control equipment. A typical
robot can offer precision of between 0.5 and 2 mm whereas a CNC
facility might claim to be ten times more accurate.
 Protection Against Oxidation
The use of high metal deposition rates brings with it the problem of
protection of the metal from oxidation during the fusion and cooling
cycles. An inert gas environment is to be maintained.
 Application of waam
 Aerospace Applications: -The early
application areas have been in aerospace.
 One of the largest 3D metal titanium parts in
the UK has been produced by Cranfield
University. Measuring 1.2m in length.
 The part forms a main structural element of
an aircraft wing structure and took just 37
hours to build from a digital model, where
previously this process would have taken
weeks.
 An even larger aluminium wing part
measuring over 2.5m in size has also been
produced in less than one day.
 Marine Applications

 Casting is the traditional

method used to create
marine propellers, but it
requires long lead times
since the process involves
making a mould, casting
it, and then processing it.
 WAAM is used to produce
marine propellers.
Fig : 1300mm diameter propeller produced by
Damen Shipyards. Fabricated from a bronze alloy
using the GTAW (TIG) process it weighs 180kg
(Photo courtesy of Delta Consultants)
 Automotive Applications
WAAM affords the possibilities
of producing complex parts for
vehicles that may not be
possible with traditional
manufacturing techniques.
 The process even offers the
opportunity to produce
prototypes on a one-off basis
quickly and cost-effectively.
 Car manufacturer Audi is Fig : Metal water connectors for
taking advantage of the benefits the AUDI W12 engine (Photo
of metallic 3D printing in courtesy of Delta Consultants)

collaboration with SLM

Solutions Group AG.
Applications of AM in various fields
 Rapid tooling
 Rapid manufacturing
 Aerospace and marine
 Automotive industry
 Textile and jewellery
 Electrical and electronic appliances
 Architecture
 Sculptures
 Biomedical applications
Rapid Tooling
Rapid Tooling (RT) is typically used to describe a process which either
uses a RP model as a pattern to create a mold quickly or uses the Rapid
Prototyping process directly to fabricate a tool for a limited volume of
production. RT is distinguished from conventional tooling as:

a) Tooling time is much shorter than that of a conventional tool.

Typically, time to first articles is below one-fifth that of conventional
tooling.

b) Tooling cost is much less than that of a conventional tool. Cost can be
below five percent of conventional tooling cost.

c) Tool life is considerably less than a conventional tool.

Rapid Investment Casting(RIC)/Rapid
Protocasting(RPC)
 Rapid Tooling (RT)using Rapid Prototyping
(RP)+Investment Casting(IC)

 Direct Rapid Tooling:

 Indirect Rapid Tooling
Investment Casting Process
Major steps of Investment casting
 1. Multiple pattern are produced.
 2.The patterns are assembled as a group on a tree where they are
gated to a central sprue.
 3. The tree of patterns is dipped in a slurry of ceramic
compounds to form a coating. Then, refractory grain is sifted
onto the coated patterns to form the shell.
 4. Step 3 is repeated for several times to obtain the desired shell
thickness and strength.
 5.After the tree has set and dried, the pattern are melted away or
burned out of the shell, resulting a cavity.
 6. Molten metal is poured into the shell to form the parts.
 7. The ceramic shell is broken away to release the castings
 8. Finally, the castings are removed from the sprue and the gate
stubs are ground off.
Rapid Tooling in Investment Casting
Indirect R T in Investment Casting
Conclusions
 Model making, Pattern making (Indirect Tooling)and or
mould making (Direct Tooling) for investment casting can
be done by Additive Manufacturing (AM) Techniques.
Selection of proper AM method is important.
 Direct Ceramic Shell Fabrication by RP reduces the
manufacturing lead time to 95 percent compared to
conventional IC. But it is a challenging task for all kind of
materials and high volume of production.
 Rapid Response Manufacturing is the recent trend of
manufacturing to reduce the product design and
development time by using AM.
 Additive Manufacturing is a smart way of Manufacturing.
New Challenging activities:
 To manufacture actual quality Metal
product at large scale directly from
CAD Model using Additive
Manufacturing concepts with less
time at competitive price to meet the
dynamic need of the customer and
create a loyal and diversified customer
base.
References:
1. Advanced Machining Processes- V.K. Jain
Allied Publishers Pvt. Ltd. (2005)
2. Advanced Methods of Machining- McGeough J.A.
Chapman and Hall , London,(1988)
3. C.M. Cheah, C.K. Chua, C.W. Lee, C. Feng & K. Totong
“Rapid Prototyping and tooling techniques : a review of
applications for Rapid Investment casting”, Int. Jr, Adv.
Manf. Technol., 2005,25, pp.308-320.
4. Chanan S. Syan & Unny Menon, “Concurrent Engineering
Concepts, Implementation and Practice, Chapman & Hall
5. D.T. Pham & S.S. Dimov, “Rapid Manufacturing”
Springer,2001
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