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Additive Manufacturing
Additive Manufacturing
Rapid Prototyping
https://www.youtube.com/watch?v=yKnlmfuMSgo
https://www.youtube.com/watch?v=dRMF9lC0tXs
Advantages
How It Works
Process Steps
Modeling
CAD Model
.STL format
The STL file format has become the Rapid Prototyping industry's defacto
standard data transmission format, and is the format required to interact with
Quickparts/3D printer.
For a simple model such as the box shown in figure 1, its surfaces can be
approximated with twelve triangles, as shown in figure 2.
The more complex the surface, the more triangles produced, as shown in
figure 3.
Support Structures
Part
Support structures
The program may also generate an auxiliary
structure to support the model during the build.
Slicer software is the tool you need to convert a 3D model into printing
instructions for your 3D printer.
It cuts the model into horizontal slices (layers), generates toolpaths to fill them
and calculates the amount of material to be extruded.
Tool Path
Building the part (Layer by
Layer)
Post Processing
(Clean and Finish the part)
Schematic of implant fabrication
With Ultrasonic
UV-Ultrasonic Vibration
Electron Beam Melting (EBM)
Numerous applications in aerospace, automotive
and medical/orthopaedic implant industries
During the EBM processing, each slice is divided
into two regions, i.e. contours and squares.
Initially the boundaries of the parts (act as
counters) are fabricated which acts as an
interface between the part and the surrounding
metallic powder.
After this the required part was built within these
contours, normally referred as squares.
The process is performed under vacuum
condition to eliminate impurities and yields high
strength properties of the finished part.
The part after its fabrication is transferred to a
special blast chamber with a pow-der recovery
system (PRS) where all the excess powder is
removed.
Further, processes such as milling, turning,
polishing and grinding can be used for surface
treatment of EBM parts
Commercial AM techniques, their
Manufacturers and Material Providers
Summary
Design for Additive Manufacturing
Material Considerations
General design considerations
Support structure design
Materials for AM
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Design Considerations
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Design Considerations
Benchmarks
Three types of benchmark parts are used for design
evaluation
Process parameters (e.g., laser power, scan speed, scan direction, material, powder size, and layer thickness)
and the microstructure (e.g., porosity, grain structure, surface roughness, precipitates, voids, defects, and residual stress)
IMPACTS Mechanical properties and performance (e.g., strength, fatigue life, ductility, hardness, and toughness)
Design of Support Structures
Support structure is an integral part for many AM
processes, and the design of support structure is no trivial
task.
The fabrication of support structure usually cause
additional time and materials
The removal of support structures requires additional
processes and poses additional design constraints to the
parts
They are required due to
the existence of the buoyancy force and the shrinkage
induced distortion
to counter the thermal residual stresses generated
during the melting–solidification processes and gravity
necessitate the need for support structures
Due to large temperature gradients that are generated
during the fabrication process
to ensure the quality and accuracy of the parts
features with overhanging angle of over 45° require
support structures (C and D) Typical geometries that
require support structures
features that are unsupported and have large
overhanging areas
Design of Support Structures