3/20/2018

ADDITIVE MANUFACTURING
1

Tool-less fabrication of product

Harlal S. Mali, PhD

Additive Manufacturing CONTENTS

4
A process manufacturing to make objects from 3D model data, usually layer upon layer,
as opposed to subtractive manufacturing Techs..(ASTM F2792-12)  Introduction
ES: Electroset FluidSLS: Selective Laser Sintering  Principle
LOM: Laminated Object Manufacturing
TSF: Topographic Shell Fabrication  Steps
LTP: Liquid Thermal Polymerization
BIS: Beam Interface Polymerization
 Processes : Classifications & Technologies
FDM: Fused Deposition Modelling
 Additive Manufacturing by industry sectors
SFP: Solid Foil Polymerization
BPM: Ballistic Particle Manufacturing  Process Capabilities
SDM: Shape Deposition Modelling
SGC: Solid Ground Curing  Advantages and Disadvantages
HLS: Holographic Surface
GPD: Generic Part Design  Applications
3DP: 3D Printing
SF: Shell Fabrication
 Conclusion
SL: Stereolithography
3DW: 3D Writing
https://www.researchgate.net/figure/Classification-of-different-additive-manufacturing-technologies-2_fig1_263929193

Two Ways for Fabrication: Introduction

5 6
Subtractive manufacturing Additive Manufacturing
 Additive manufacturing techniques create 3-D objects directly from a
computer model, depositing material only where required.
 These new techniques, while still evolving, are projected to exert a
profound impact on manufacturing. They can give industry new design
flexibility, reduce energy use, and shorten time to market.
 The process is often called 3-D printing, Rapid Prototyping, Rapid
Tooling or digital manufacturing because of similarities to standard
desktop printing.
 Interest in additive techniques has grown swiftly as applications have
progressed from RP to the production of end-use products.
 Can now use metals, polymers, composites, or other powders to “print”
a range of functional components, layer by layer, including complex
structures that cannot be manufactured by other means.

1
 3/20/2018

All AM (RP) techniques employ the basic five-

Process Principle step process.
7

1. Create a CAD model of the design

2. Convert the CAD model to STL format

(stereolithography)

3. Slice the STL file into thin cross-sectional layers

4. Construct the model one layer atop another

5.
8
Clean and finish the model

AM / RP SyStemS
 CAD Model Creation:
 First,
the object to be built is modeled using a Computer-
Aided Design (CAD) software package.
 Solidmodelers, such as Pro/ENGINEER/CATIA
/Autodesk Inventor, tend to represent 3-D objects more
accurately than wire-frame modelers such as AutoCAD,
and will therefore yield better results.
 This process is identical for all of the RP build techniques.
9 10
AM SyStemS
 Conversion to STL Format:
 To establish consistency, the STL (stereolithography,
the first RP technique) format has been adopted as the
standard of the rapid prototyping industry.
 Convert the CAD file into STL format. This format
represents a three-dimensional surface as an assembly
of planar triangles
 STL files use planar elements, they cannot represent
curved surfaces exactly. Increasing the number of
triangles improves the approximation

A M Systems A M Systems
 Slice the STL File:  Layer by Layer Construction:
 Inthe third step, a pre-processing program
prepares the STL file to be built.  The fourth step is the actual construction of the
part.
 The pre-processing software slices the STL model
into a number of layers from 0.01 mm to 0.7 mm
thick, depending on the build technique.  AM(RP) machines build one layer at a time from
polymers, paper, or powdered metal.
 The program may also generate an auxiliary
structure to support the model during the build.
Supports are useful for delicate features such as  Most machines are fairly autonomous, needing
overhangs, internal cavities, and thin-walled
sections. little human intervention.
11 12

2
 3/20/2018

A M Systems ClassifiCation of a M teChnologies

 Clean and Finish:
 The final step is post-processing. This involves removing
the prototype from the machine and detaching any
supports.
 Some photosensitive materials need to be fully cured
before use
 Prototypes may also require minor cleaning and
surface treatment.
 Finishing, Sanding,Sealing, and/or Painting the model
will improve its appearance and durability.
13 14
 The RP classification used here is based on the form
of the starting material:
 Liquid-based
 Stereo lithography (STL)
 Solid-based
 Fused deposition modeling (FDM)
 Laminated object manufacturing (LOM)
 Powder-based
 Selective laser sintering (SLS)
 Three dimensional printing (3-D P)

Liquid-Based a M systeMs
 Stereolithography(STL):- fabricating a solid
plastic part out of a photosensitive liquid
polymer(liquid epoxy or Acrylate resin) using
a directed laser beam to solidify the polymer.

 Part fabrication is accomplished as a series of

layers - each layer is added onto the previous
layer to gradually build the 3-D geometry
15 16
 Fig.1 -STEREOLITHOGRAPHY

STL Part Build Time in STL

 Each layer is 0.076 mm to 0.50 mm thick Time to complete a single layer :
Thinner layers provide better resolution and Ai
more intricate shapes; but processing time is Ti   Td
vD
longer where Ti = time to complete ith layer;
 Starting materials are liquid monomers Ai = area of ith layer;
v = average scanning speed of the laser beam at the
 Polymerization occurs on exposure to UV surface;
light produced by laser scanning beam D = diameter of the “spot size,” assumed circular; and
Scanning speeds ~ 500 to 2500 mm/s Td = delay time between layers to reposition the worktable
17 18

3
 3/20/2018

Laminated Object manufacturing

Solid-Based a M systeMs Solid physical model made by stacking layers of
sheet stock, each an outline of the cross-sectional
shape of a CAD model that is sliced into layers
 Solid-based RP systems include the  Starting sheet stock includes paper, plastic,
following processes: cellulose, metals, or fiber-reinforced materials
 Laminated object manufacturing  The sheet is usually supplied with adhesive backing
as rolls that are spooled between two reels
 Fused deposition modeling
 After cutting, excess material in the layer remains in
place to support the part during building

19 20

Fused deposition Modeling (FdM)

 A long filament of wax or polymer is extruded onto
existing part surface from a work-head to complete each
new layer
 Work head is controlled in the x-y plane during each layer
and then moves up by a distance equal to one layer in the
z-direction
 Extruded material is solidified and cold welded to the
cooler part surface in about 0.1 s
 Part is fabricated from the base up, using a layer-by-layer
Fig. 2- Laminated object manufacturing
procedure
21 22

Powder-Based a M systeMs

 Powder-based RP systems include the

following:
 Selective laser sintering
 Three dimensional printing

Fig 3: Schematic diagram of fused deposition modeling

23 24

4
 3/20/2018

Selective laSer Sintering (SlS) BASIC SCIENCE BEHIND SLS

 Moving laser beam sinters heat-fusible powders in
areas corresponding to the CAD geometry model one
layer at a time to build the solid part
 After each layer is completed, a new layer of loose
powders is spread across the surface
 Layer by layer, the powders are gradually bonded by
the laser beam into a solid mass that forms the 3-D
part geometry
 In areas not sintered, the powders are loose and can be
poured out of completed part
25

SLS HOW SLS WORKS?



 Selective Laser Sintering (SLS) was developed at the University of

Texas in Austin, by Carl Deckard. The technology was patented in
1989
 Originally sold by DTM Corporation. DTM was acquired by 3D Systems
in 2001
 Uses a laser as the power source to sinter powdered material
(typically metal), aiming the laser automatically at points in space
defined by a 3D model, binding the material together to create a solid
structure.
 SLS works on an "additive" principle by laying down material in
layers; a powder based technology is a directed energy beam to
sinter powder material to produce a part.

SINTERING SINTERING PROCESS

 Sintering is thermal treatment of fine-grained material at a temperature below
the melting point of the main constituent, for the purpose of increasing its grain  Growth of necks, formed between spherical particles during sintering, has been
size and strength by bonding together the particles. studied experimentally.
 During sintering atomic diffusion takes place and the welded areas formed  According to a theoretical model developed by C.G. Kuczynski, the growth of these
during compaction grow until eventually may be lost completely. necks is governed by the following law:
 Re-crystallization and grain growth may follow, and the pores tend to become
rounded and the total porosity, as a percentage of the whole volume, tends to
decrease.  Where, a = particle diameter, x = neck width, t = sintering time.
 The sintering process is governed by the following parameters: Kuczynski’s model predicts: n = 2 for viscous or plastic flow, n = 3 for evaporation/
 Temperature and time, condensation, n = 5 for volume diffusion, n = 7 for surface diffusion.
 Geometrical structure of the powder particles,
 Composition of the powder mix,
 Density of the powder compact,
 Composition of the protective atmosphere in the sintering furnace.
The sintering process passes through two different stages:
 An early stage with local bonding (neck formation) between adjacent particles,
 A late stage with pore-rounding and pore shrinkage.

5
 3/20/2018

3D printing BASIC SCIENCE OF 3D PRINTING:-

PRINTING:-

 Works on the principal of process of binder jetting.

 A continuous powder layers are moved with the help of a piston.
 In between those layers with the help of liquid binder from a jet
strength is provided to the pattern.
 The Skelton produced after the process is called as the green part.
 Used for some other post process like infiltration and sintering.

1.Vat Photopolymerisation:- 2. Material Jetting:-

3. Material Extrusion:- Parameters governing the science of 3D P

 Binder selection:-binder interaction with candidate powders

 binder residue in the debinding post-process
 Powder selection:-Powders are selected based on their
particle size distribution, morphology and chemical
composition
 Material selection:-
 Metals; stainless steel
 Polymer: ABS, PA, PC
 Ceramic: glass
 Skelton or green part criteria

6
 3/20/2018

HOW 3D PRINTER WORKS? A COMPLETE FLOW DIGRAM OF PROCESS:-

RP/RT and aM aPPlicaTions Design Applications

 Designers are able to confirm their design by
 Applications of RP/RT can be building a real physical model in minimum time
classified into three categories: using RP

1. Design  Design benefits of RP:

 Reduced lead times to produce prototypes
2. Engineering analysis and planning
 Improved ability to visualize part geometry
3. Tooling and manufacturing  Early detection of design errors
 Increased capability to compute mass properties
 End Product Manufacturing (AM)
39 40

Engineering Analysis and Planning Additive Manufacturing by Industry Sectors:

 Existence of part allows certain engineering analysis and 42
planning activities to be accomplished that would be more
difficult without the physical entity
 Comparison of different shapes and styles to determine aesthetic appeal
 Wind tunnel testing of streamline shapes
 Stress analysis of physical model
 Fabrication of pre-production parts for process planning and tool design

Tooling application
Rapid tool making (RTM) when RP is used to fabricate
production tooling
41

7

Organisations Involved In Additive Manufacturing
 3D Technique, Gujarat (www.enggtechnique.com/ )
 3Ding, Delhi (https://www.3ding.in/ )
 Think 3D, Hyderabad (https://www.think3d.in/ )
 3DigiPrints, Mumbai (www.3digiprints.com/ )
 Global 3D Labs, Hyderabad (www.global3dlabs.com/)
 3D Bazaar, Gurugram (www.3dbazaar.in )
 Aha 3D, Jaipur (https://aha3d.in/ )
 NTU Additive Manufacturing Centre (www.sc3dp.ntu.edu.sg/ )
 TRUMPF, USA (https://www.trumpf.com/ )
 Reynolds Advanced Materials, USA
(https://www.reynoldsam.com/ )
 Wohlers Associates, USA (https://wohlersassociates.com/3D-
printing.html )
 Cincinnati Inc, USA (https://www.e-ci.com/ )
Process capabilities
45
 AM can be a fast and less expensive way to create small
runs of products than other processes currently being
used.
 It also can create virtually any shape with a machine as
small as a desktop printer, in some cases.
 It can builds up the model with material in the form of
liquid, powder or sheet metal.
 In its conception, the process was fairly slow, but as a
result of many companies’ hard work, the process has
greatly improved in many areas, including speed, and
advances are being made every day.
Advantage
47
 Increased part complexity
 Digital design and manufacturing
 Complexity is free
 Instant production on a global scale
 Waste reduction
 Design freedom
 Reduced assembly
3/20/2018
Case Study on Future of Additive Manufacturing
 Major Applications include: Implantations, Dental crowns, Bio-inks
(cells to tissue), PCBs, Automobiles, Space, Apparels, Art, Education
and R&D etc.
 Scientists grow an ear from living tissue: The organs were made in
the laboratory in the hope of using them to replace the damaged
or missing body parts of patients.
http://www.independent.co.uk/news/science/scientists-grow-an-
ear-from-living-tissue-8738618.html
 3D Printing In Zero-G Technology Demonstration (12.06.2017)
(https://www.nasa.gov/mission_pages/station/research/experime
nts/1115)
 Elon Musk shows how 3D printing powers mission to colonize mars
https://3dprintingindustry.com/news/elon-musk-shows-3d-printing-
powers-mission-colonize-mars-96417/
Problems with Additive Manufacturing
 Part accuracy:
 Staircase appearance for a sloping part surface due
to layering
 Shrinkage and distortion of RP parts
 Limited variety of materials in RP
 Mechanical performance of the fabricated parts is
limited by the materials that must be used in the
RP process
46
Disadvantage
48
 Limiting of raw materials.
Comparing to the conventional methods of
production AM technologies has very limited raw
materials that can be used to produce parts. But
there is always improving new materials coming to
the market.
 Surface finish.
The produced parts by AM technologies need
finishing before they can be used.
8
 3/20/2018

Continue…….. APPLICATION
49 50

 Not economic for high volume production. Industry is taking advantage of AM to produce
AM technologies still can not compete with the plastic, metal, or composite parts and custom
conventional production methods when it comes to the
mass production. AM still economic when it comes to the products without the cost, time, tooling, and
design phase or for low volume products or rapidly overhead required in the traditional machining or
changing high volume products. manufacturing processes.
 Limitation of the part size.
 AM is reducing the aerospace industry’s
The produced parts by AM technologies still have very
limited sizes. On the other hand, a lot of improvements important materials measure, the “buy-to-fly”
happing to overcome this problem in the new AM ratio—pounds of material needed to make one
systems. pound of aerospace-quality material—by more
than half.

APPLICATION SUMMARY
51 52

 Many military applications also often require  AM represents a whole new paradigm and range of
miniaturized, custom-designed units in relatively small opportunities for design, functionality, and cost. The AM field
numbers. Additive manufacturing also supports rapid represents an exciting and rapidly emerging industry.
development and production to meet the military’s  AM for metals is rapidly developing through a range of
specialized functional requirements. powder bed and wire-fed technologies
 For the automotive industry, additive manufacturing  Additive Manufacturing Consortium (AMC) is poised for
holds great promise. Vehicle bodies and engines could growth into many manufacturing sectors
be made using fewer parts and rapidly redesigned to
 Looking for potential applications within the oil and gas
minimize failures. The traditional assembly line could
market that fit one or more of the following scenarios and
even become a thing of the past for some industries.
opportunities;
 Adding features to low yield castings and forgings

Reference Other Reference

53 54

1. Ian D. Harris , “Development and Implementation of Metals Additive Manufacturing” Feb. 10, 2011.
i. Wohlers, T., “Wohlers Report 2010”, Wohlers Associates, Ft. Collins, 2010.
2. Nanond Nopparat, Babak Kianian , “Resource Consumption of Additive Manufacturing ii. “3D Printed Prosthetics Company Bespoke Acquired By 3D Systems,” Singularity Hub, 8 June
Technology”, Karlskrona, Sweden ,2012 . 2012.
3. “3-D printing could remake U.S. manufacturing,” USA Today, 10 July 2012. iii. http://singularityhub.com/2012/06/08/3d-printed-prosthetics-company-bespoke-acquired-by-
3d-systems/
4. http://www.usatoday.com/money/industries/manufacturing/story/2012-07-10/digital-
manufacturing/56135298/1 iv. Bourell, D. L., Leu, M. C., and Rosen, D. W. Eds., “Roadmap for Additive
5. Additive Manufacturing Technology Roadmap for Australia, Commonwealth Scientific and Industrial Manufacturing, Identifying the Future of Freeform Processing”, The University of
Research Organisation,March 2011, p. 22. Texas at Austin Laboratory for Freeform Fabrication, Austin, 2009.
6. http://www.enterpriseconnect.gov.au/media/Documents/Publications/Additive%20Manufacturing v. T. Wohlers,, Wohlers Associates, Inc.,Fort Collins, Colorado USA , Wohlers Report
%20Tech%20Roadmap.pdf 2009
7. Thomas Campbell ,Christopher Williams ,” straTegic forsight report “ ,2011.
vi. Holly Shulman, ” Introduction to Additive Manufacturing ceramic industry”
8. The Economist, “Solid Print: Making Things with a 3D Printer Changes the Rules of Manufacturing,” 21 December 2012
April 2012.
9. Terry Wohler , “Worldwide Trends in Additive Manufacturing”, RapidTech 2009. vii. “Additive Manufacturing Goes Mainstream,” IndustryWeek, 10 March 2012.
10. “Next 3-D Frontier: Printed Plane Parts,” WSJ.com, 14 July 2012. viii.

11. http://online.wsj.com/article/SB1000142405270230393340457750508029685889 http://www.industryweek.com/articles/additive_manufacturing_goes_mainstream_

6.html?KEYWORDS=boeing+3D+printing 26805.aspx?ShowAll=1