Subtractive manufacturing

Subtractive manufacturing is nothing but a material removal process, wherein

material is removed using external force or by any other means of operation.

Based on the type of operation, these processes are subdivided into three
parts.

(a) Conventional machining : Conventional machining is the oldest process,

where a sharp cutting tool is used to mechanically cut the material to achieve
the desired geometry by having a relative motion with respect to material.

(b) Abrasive process : removal of material by the action of hard abrasive

particles (fine, sharp particles) on the surface that is to be machined; such a
setup comes under the abrasive process.

(c) Non-traditional process : material removal is achieved using various

energy forms other than conventional and abrasive processes; such
operations are called non-traditional processes.
Subtractive manufacturing is not restricted to materials that can be machined
until there is a tool that is harder and has sufficient toughness to stand the
mechanical force, or else we can use other forms of energy that come under
non-traditional processes.

Additive Manufacturing

In additive manufacturing, instead of removing material from the job, the job
is created by adding the material in a constrained space and way that follows
the shape of the geometry we desire; hence, no material is wasted during this
process. Example : fused deposition modeling (FDM), stereolithography (SLA),
Selective laser sintering (SLS), binder jetting, direct metal laser sintering
(DMLS) and multi jet fusion (MJF).

Fused deposition modeling (FDM) : Fused deposition modeling is the most

popular way to create a 3D printing machine, where it uses a layer-by-layer
deposition technique, in which molten polymers or ceramics are extruded
through a nozzle with a small orifice, which merges with the material on the
previous layer. The pattern for each layer is controlled by mechanical
manipulation of the x-y position of the nozzle and can be different or
arbitrary for each deposited layer. Due to which FDM printers are in a
continuous cycle of heating, extruding and moving according to the
coordinates of the model which has been fed to them. This is done by
following the below standard workflow which is accepted by various FDM
printers.
FDM printers are not only useful for rapid prototyping but also cheap in price
and easy to operate. Due to the development of CAD software and 3D printers,
it is now easy to perform this task with just a few clicks.

The only disadvantage is that material selection for the moment is less due to
the thermal conductivity and viscosity of the material, leading to insufficient
heating and disintegration of fused material because of temperature variation
in deposited and extruded material.

How Does Selective Laser Sintering (SLS) 3D Printing Work?

Selective laser sintering (SLS) : Selective laser sintering printers uses laser
technology guided by motorized mirror pointing on a table wherein it is
coated by an powder of the material which is to be printed this powder is
usually stored into containers adjacent to the table and is coated using a
slider which slides from one container to another creating a thin layer of
powder on the table and to speed up the process the powder is preheated
below its melting point.before reaching the table.

Once the powder is laid on the table the laser scans the CAD model for a thin
horizontal cross section once it scans the model it then drives the motorized
mirror to create the same pattern on the table covered with powder, and as
the powder is preheated before using laser hence it fuses quickly resulting in
binding of powder which is been exposed to laser. Once the laser finishes
drawing a pattern The platform then lowers by one layer into the build
chamber, typically between 50 to 200 micrometers, and the process repeats
for each layer until parts are complete.

stereolithography (SLA) : Stereolithography is a rapid prototyping process that

involves building a 3D part layer by layer using a liquid polymer material that
solidifies with the assistance of a laser.
The polymer used in this process is photosensitive and solidifies when
exposed to ultraviolet light or UV rays.

This laser is directed at the working surface on which the part is to be

printed, once it solidifies the table descends downward for new liquid resin to
be cured on the top of the solidified resin this process is repeated again until
the model is finished.

Scanning & Projection Stereolithography process (SPSLA) : Scanning and

projection stereolithography is a combination of the scanning SLA technique
and the projection SLA process.
The projection SLA process utilizes an LCD display enclosed in a chamber
with reflectors facing the LCD. CAD software controls the display, which
regulates the absorption of UV rays. Mirrors reflect the UV rays onto the LCD
display. The degree of UV absorption depends on the pixel's brightness. Bright
pixels redirect all UV rays to the working table, while dark pixels absorb UV
light, generating the desired pattern. This technique allows the user to create
high-resolution parts due to the LCD's resolution. And the process is relatively
faster compared to others due to the creation of each layer in one go instead
of incrementally changing positions for creating a single layer, which is
time-consuming.

Whereas in scanning SLA process a stationery beam of light mainly UV rays

is focused on to a working table which is free to move in all three axes to
create the part.

Hence the combination of high resolution parts and long area coverage of
both PSLA and SSLA are merged into one single machine to increase the
productivity of a machine workshop.

Lec 19: Laser Scanning Stereolithography

Laminated Object Manufacturing(LOM) : LOM technology uses

adhesive-coated paper, plastic, or metal laminates as a 3D printing medium.
These sheets of material are glued together layer-by-layer and cut into shape
using a knife or with laser cutting.

Once a layer has been glued into place and the required dimensions drawn,
the build platform moves down so another layer of material can be rolled into
position with the heated roller. This process is repeated until the model or
prototype is complete.

Digital Light Processing(DLP) : Digital light processing is a chipset used in

SLA printing technology where it is used to create projection of light such that
it looks like a miniature mask but is created digitally using optical
micro-electro-mechanical technology that uses a digital micromirror device
(DMD). This digitally created mask can then be used to cure the liquid resin
for less waiting time and high resolution parts.

[ NOT IMPORTANT ]
Forming Process :

Forming Process involves plastic deformation of material to forcefully take the

Shape of the die or to shear the material according to the punch.

This process requires a heavy duty machine which can create high forces
such that the material can transform into its plastic state on a stress-strain
curve, which is beyond the elastic limit.

Further it is classified into various processes depending on the requirements.

Hybrid Processes :

A process that combines both additive and subtractive manufacturing on one

single machine such operation and setup comes under hybrid manufacturing.

Example : Removal of Metal powder from a metal deposition process or

grinding a 3d printed part for polishing.

Rapid prototyping : Rapid prototyping is a method used to create a basic

version of a product quickly in order to test and evaluate its design,
functionality, and usability.

Advantages of Rapid prototyping:

1) Speed : It allows for quick creation of prototypes, saving time in the process
planning for manufacturing.

2) Early Feedback : Users can provide feedback early on, which helps in
refining the final product.

3) Cost-Effective : Reduces overall costs by identifying design flaws and

usability issues early.

4) Visualization : Provides a tangible model for designers and stakeholders to

understand the product better.

Disadvantages of Rapid prototyping :

1) Simplicity : Prototypes may lack complexity and details of the final product.

2) Limited Functionality : Some functionalities may not be achievable in the

prototype stage.
3) Potential Misinterpretation : Users might misunderstand the purpose or
capabilities of the prototype.

4) Resource Dependency : Requires skilled personnel and appropriate

resources.

Applications :

1) Product designing : used for design evaluation in the early stage of a

product.

2) Architecture : Architects use prototypes to visualize building designs.

3) Education : Used in engineering, science and medical disciplines to

demonstrate concepts, design and structure.

In essence, rapid prototyping is about quickly making a basic model to see

how well a product works and then improving it based on what you learn.

Injection molding

Injection molding is a process in which a polymer is heated to a highly plastic

state and forced to flow under high pressure into a mold cavity, where it
solidifies. The molded part, called a molding, is then removed from the cavity.
The process produces discrete components that are almost always net shape.
The production cycle time is typically in the range of 10 to 30 sec, although
cycles of 1 min or longer are not uncommon for large parts. Also, the mold
may contain more than one cavity, so that multiple moldings are produced
each cycle.

Complex and intricate shapes are possible with injection molding. The
challenge in these cases is to fabricate a mold whose cavity is the same
geometry as the part and that also allows for part removal.
Investment casting

Investment casting, also known as precision casting or lost-wax casting, is a

manufacturing process in which a wax pattern is used to shape a disposable
ceramic mold. A wax pattern is made in the exact shape of the item to be
cast. This pattern is coated with a refractory ceramic material. Once the
ceramic material is hardened, it is turned upside-down and heated until the
wax melts and drains out. The hardened ceramic shell becomes an
expendable investment mold. Molten metal is poured into the mold and is left
to cool. The metal casting is then broken from the spent mold.

This process has a higher surface finish due the wax pattern which helps in
creating a smooth and strong mold compared to sand casting.

Direct Digital Manufacturing

Direct Digital Manufacturing (DDM) is a process that produces parts directly

from a CAD file by taking the advantage of additive manufacturing
technologies to accomplish this objective.
This process helps in reducing the time taken from the design phase of a
product to manufacturing. But at a coast of high quality and low production
rate.