ADDITIVE

MANUFACTURING
PRESENTED BY
NAZMA AMRIN
CONTENTS
Introduction.
Conventional Machining Processes.
Development of CAD/CAM systems.
 Advantages and Limitations.
Concurrent Engineering.
INTRODUCTION
 Definition: Additive Manufacturing(AM) refers to a
process by which digital 3Ddesign data is used to build up
a component in layers by depositing material. (from the
International Committee F42 for Additive Manufacturing
Technologies, ASTM)..
Additive manufacturing is
the formalized term for what
used to be called rapid
prototyping and what is
popularly called 3D
Printing.
Definition: It is defined as
the process of joining
materials to make objects
from 3D model data, usually
layer upon layer, as opposed
to subtractive manufacturing
methodologies.

Figure 1.1 AM process

Common to AM technologies is the use of a computer,
3D modeling software (Computer Aided Design or
CAD), machine equipment and layering material. 
Once a CAD sketch is produced, the AM equipment
reads in data from the CAD file and lays downs or
adds successive layers of liquid, powder, sheet material
or other, in a layer-upon-layer fashion to fabricate a 3D
object.
The term AM encompasses many technologies
including subsets like 3D Printing, Rapid Prototyping
(RP), Direct Digital Manufacturing (DDM), layered
manufacturing and additive fabrication.
Early use of AM in the form of Rapid Prototyping
focused on preproduction visualization models.
More recently, AM is being used to fabricate end-use
products in aircraft, dental restorations, medical
implants, automobiles, and even fashion products.
THE GENERIC AM PROCESS
AM involves a number of steps that move from the
virtual CAD description to the physical resultant part.
 Different products will involve AM in different ways
and to different degrees.
Some of the products made by additive
manufacturing
Figure 1.2 Generic process of CAD to part, showing all eight stages
Basically AM process involve following eight steps:
Step 1: CAD : All AM parts must start from a software model that
fully describes the external geometry. This can involve the use of
almost any professional CAD solid modeling software, but the
output must be a 3D solid or surface representation.
Step 2: Conversion to STL :Nearly every AM machine accepts
the STL file format, which has become a de facto standard, and
nowadays nearly every CAD system can output such a file format.
This file describes the external closed surfaces of the original
CAD model and forms the basis for calculation of the slices.
Step 3: Transfer to AM Machine and STL File Manipulation:
The STL file describing the part must be transferred to the AM
machine. Here, there may be some general manipulation of the file
so that it is the correct size, position, and orientation for building.
Step 4: Machine Setup: The AM machine must be properly
set up prior to the build process. Such settings would relate to
the build parameters like the material constraints, energy
source, layer thickness, timings, etc.
Step 5: Build: Building the part is mainly an automated
process and the machine can largely carry on without
supervision. Only superficial monitoring of the machine needs
to take place at this time to ensure no errors have taken place
like running out of material, power or software glitches, etc.
Step 6: Removal: Once the AM machine has completed the
build, the parts must be removed. This may require interaction
with the machine, which may have safety interlocks to ensure
for example that the operating temperatures are sufficiently
low or that there are no actively moving parts.
Step 7: Post-processing: Once removed from the
machine, parts may require an amount of additional
cleaning up before they are ready for use. Parts may be
weak at this stage or they may have supporting features
that must be removed. This therefore often requires time
and careful, experienced manual manipulation.
Step 8: Application: Parts may now be ready to be used.
However, they may also require additional treatment
before they are acceptable for use. For example, they may
require priming and painting to give an acceptable surface
texture and finish.
Conventional Machining Processes
Machining is any of various processes in which a
piece of raw material is cut into a desired final shape
and size by a controlled material-removal process.
The processes that have this common theme,
controlled material removal, are today collectively
known as subtractive manufacturing.
The three principal machining processes are classified
as turning, drilling and milling. Other operations
falling into miscellaneous categories include shaping,
planing, boring, broaching and sawing.
ADDITIVE V/S SUBTRACTIVE
MANUFACTURING

Figure: Features that represent problems using CNC machining

Development of CAD/CAM systems
The real development of CAD/CAM systems started in
the 1950s.
The development of CAD and CAM and particularly
the linkage between the two overcame traditional NC
shortcomings in expense, ease of use, and speed by
enabling the design and manufacture of a part to be
undertaken using the same system of encoding
geometrical data.
This innovation greatly shortened the period between
design and manufacture and greatly expanded the scope
of production processes for which automated machinery
could be economically used.
CAD technology has rapidly improved
along the following
Realism: With lighting and shading effects, ray tracing
and other photorealistic imaging techniques, it is
becoming possible to generate images of the CAD models
that are difficult to distinguish from actual photographs.
Usability and user interface : Early CAD software
required the input of text based instructions through a
dialog box. Instructions are issued through the use of
drop-down menu systems and context-related commands
Engineering content: With solid modeling CAD it is
possible to calculate the volumes and masses of models,
investigate fits and clearances according to tolerance
variations, and to export files with mesh data for FEA
Speed: CAD systems are constantly being optimized in
various ways, mainly by exploiting the hardware
developments of computers.
Accuracy: If high tolerances are expected for a design then
it is important that calculations are precise. High precision
can make heavy demands on processing time and memory.
Complexity: All of the above characteristics can lead to
extremely complex systems. It is a challenge to software
vendors to incorporate these features without making them
unwieldy and unworkable.
Advantages of additive manufacturing
Freedom to design and innovate without penalties.
Rapid iteration through design and permutations.
Excellent for mass customization.
Elimination for tooling.
Green manufacturing .
Minimal material waste.
Energy efficient .
Enables personalize manufacturing
Short production cycle time
Disadvantages of additive
manufacturing
Unexpected pre and post-processing requirements.
High process cost.
Lack of industry standards.
Low speed, not suitable for mass production.
Inconsistent material.
Limited number of materials.
High equipment cost for high end manufacturing.
Concurrent engineering
Concurrent engineering (CE) is a work methodology
emphasizing the parallelization of tasks (i.e. performing
tasks concurrently), which is sometimes called
simultaneous engineering or integrated product
development (IPD) using an integrated product team
approach.
Concurrent engineering is synonymous with simultaneous
engineering it means that people who design or manufacture
products work under same targets and the same sense of
values to tackle the same problems enthusiastically from the
early phase.
A Framework for Concurrent Engineering
Traditional "Waterfall" or Sequential Development
Method vs. Iterative Development Method in
concurrent engineering
Why concurrent engineering?
Increasing product variety and technical complexity
that prolong the product development process and
make it more difficult to predict the impact of design
decisions on the functionality and performance of the
final product.
Increasing global competitive pressure that results
from the emerging concept of reengineering.
The need for rapid response to fast-changing
consumer demand.
Large organizations with several departments working
on developing numerous products at the same time.
New and innovative technologies emerging at a very
high rate, thus causing the new product to be
technological obsolete within a short period.