Additive Manufacturing

Department of Mechanical
Engineering
Outline

Introduction to Additive Manufacturing

Classification of Additive Manufacturing Systems

Introduction to Reverse Engineering

Additive Manufacturing

► Additive Manufacturing (AM) refers to a process by

which digital 3D design data is used to build up a
component in layers by depositing material.
► The term AM encompasses many technologies including
subsets like 3D Printing, Rapid Prototyping (RP), Direct
Digital Manufacturing (DDM), layered manufacturing and
additive fabrication.
► AM application is limitless. 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.
Additive Manufacturing contd.
Basic structure of additive manufacturing and
its subcategories
Some Examples
Some Examples contd.
Some Examples contd.
Some Examples contd.
Additive vs Subtractive Manufacturing
Additive vs Subtractive Manufacturing
contd.
Evolution of AM
Technologies
Evolution of AM Technologies
contd.
Current and Potential industries for
Additive Manufacturing
Pros and Cons of AM
AM Benefits: Weight Reduction
AM Benefits: Complexity for
Free
AM Benefits: Customized Medical Products
Future: Home Manufacturing
Generic AM Process
Generic AM Process contd.
Data path for additive manufacturing
Generation of Geometrical Layer Information on Single
Layers

► To produce three-dimensional models by layer-oriented

additive manufacturing processes, the 3D CAD solid must
be mathematically split into the same layers as those
produced physically by the AM machine. This process is
known as ”slicing.”
► There are two basic methods of doing this:
1) Triangulation, which leads to the STL format
2) Direct cutting in the CAD system, which leads to the CL
(SLI) format
STL format

► STL (STereoLithography) is a file format native to

the stereolithography CAD software.
► It is widely used for rapid prototyping, 3D printing
and computer-aided manufacturing.
► The main purpose of the STL file format is to encode
the surface geometry of a 3D object.
► It encodes this information using a simple concept
called ”tessellation”.
Tessellation

► Tessellation is the process of tiling a surface with one or

more geometric shapes such that there are no overlaps or
gaps.
► Tessellation can involve simple geometric shapes or very
complicated (and imaginative) shapes.
Valid vs. Invalid Tessellated
Models
Exploiting tessellation to encode surface
geometry
► The basic idea is to tessellate the 2 dimensional outer
surface of 3D models using tiny triangles (also called
”facets”) and store information about the facets in a file.
► For example, if you have a simple 3D cube, this can be
covered by 12 triangles and 3D model of a sphere, then it
can be covered by many small triangles, as shown in the
image below.
Exploiting tessellation to encode surface geometry
contd.
► Here is another example of a very complicated 3D
shape which has been tessellated with triangles.
How does an STL file store information about
facets?
► The STL file format provides two different ways of storing
information about the triangular facets that tile the object
surface.
1) ASCII encoding
2) The binary encoding
► In both formats, the following information of each triangle is
stored:
1) The coordinates of the vertices.
2) The components of the unit normal vector to the triangle.
The normal vector should point outwards with respect to the
3D model.
The ASCII STL file format
► The ASCII STL file starts with the mandatory
line: solid < name >
► The file continues with information about the covering
triangles. Information about the vertices and the
normal vector is represented as follows:
facet normal nx ny
nz outer loop
vertex v1x v1y v1z
vertex v2x v2y v2z
vertex v3x v3y
v3z
endloo
p
endfacet
► Here, n is the normal to the triangle and v1, v2 and v3 are
the vertices of the triangle.
► The file ends with the mandatory line:
The binary STL file format

► If the tessellation involves many small triangles, the

ASCII STL file can become huge. This is why a more
compact binary version exists.
► The binary STL file starts with a 80 character header.
UINT8[80] - Header
UINT32 - Number of triangles
► The information about the triangles follow subsequently.
The file simply ends after the last triangle.
foreach triangle
REAL32[3] - Normal vector
REAL32[3] - Vertex 1
REAL32[3] - Vertex 2
REAL32[3] - Vertex 3
UINT16 - Attribute byte count
end
Special rules for the STL
format
► The STL specification has some special rules for
tessellation and for storing information.
► The vertex rule: The vertex rule states that each
triangle must share two vertices with its neighboring
triangles.
Special rules for the STL format
contd.
► The orientation rule: The orientation rule says that the
orientation of the facet (i.e. which way is ”in” the 3D
object and which way is ”out”) must be specified in two
ways.

► The triangle sorting rule: The triangle sorting rule

recommends that the triangles appear in ascending z-
value order.
► The all positive octant rule: The all positive octant rule
says that the coordinates of the triangle vertices must all
be positive.
Optimizing an STL file for best 3D printing
performance
► The STL file format approximates the surface of a
CAD model with triangles.
► The approximation is never perfect, and the facets
introduce coarseness to the model.
► It is therefore very important to find the right
balance between file size and print quality.
Advantages and Disadvantages of STL File
Format
Classification of Additive Manufacturing Systems

► The Better way is to classify AM systems broadly by the

initial form of its material, all AM Systems can be easily
categorised into
1) Liquid Based
2) Solid Based
3) Powder Based
Classification of Additive Manufacturing Systems
Liquid Based Additive Manufacturing
Systems

► Building material is in the liquid state.

► The following AM Systems fall into this category:
1) Stereolithography Apparatus(SLA)
2) PolyJet 3D printing
3) Multijet Printing(MJP)
4) Solid Object Ultravoilet-Laser Printer(SOUP)
5) Rapid Freeze Prototyping
► 1) and 4) are widely used method.
Solid Based Additive Manufacturing
Systems

► Building material is in the Solid state (except powder).

► The solid form can include the shape in the forms of
wire, rolls, laminates and pellets.
► The following AM Systems fall into this category:
1) Fused deposition modeling (FDM)
2) Selective Deposition Lamination (SDL)
3) Laminated Object Manufacturing (LOM)
4) Ultrasonic Consolidation
Powder Based Additive Manufacturing
Systems

► Building material is Powder(grain like form).

► All Powder Based AM Systems employ the
joining/binding method.
► The following AM Systems fall into this category:
1) Selective Laser Sintering(SLS)
2) ColorJet Printing(CJP)
3) Laser Engineered Net Shaping (LENS)
4) Electron Beam Melting(EBM) etc.
Important Technologies of AM

► In the next few slides, we are going to discuss these three

AM technologies
1) Stereolithography Apparatus(SLA)
2) Fused deposition modeling (FDM)
3) Selective Laser Sintering(SLS)
Stereolithography

► One of the most important additive

manufacturing technologies currently available.
► The first ever commercial RP systems were resin-
based systems commonly called stereolithography or
SLA.
► The resin is a liquid photosensitive polymer that cures
or hardens Stereolithography when exposed to
ultraviolet radiation.
► This technique involves the curing or solidification of a liquid
photosensitive polymer through the use of the irradiation
light source.
► The source supplies the energy that is needed to induce a
chemical reaction (curing reaction), bonding large no of
small molecules and forming a highly cross-linked polymer
Stereolithography contd.
Stereolithography contd.
Stereolithography contd.

► Facts About SLA

1) Each layer is 0.076 mm to 0.50 mm thick
2) Starting materials are liquid monomers
3) Polymerization occurs on exposure to UV light produced by
laser scanning beam
- Scanning speeds - 500 to 2500 mm/s
► Part Build Time in SLA
Time to complete a single layer :

i
Ti = + d (1)
A
vD
T
where T i = time to complete layer i; Ai = area of layer i; v =
average scanning speed of the laser beam at the surface; D =
diameter of the ”spot size”, assumed circular; and Td = delay
time between layers to reposition the worktable
Stereolithography contd.

► Time to build a part ranges from one hour for small parts
of simple geometry up to several dozen hours for complex
parts
► SLA Build Cycle Time :
Σnl
Tc = Ti (2)
i =1

where Tc = STL build cycle time; and nl = number of layers

used to approximate the part
SLA 3D Printing Product
Fused deposition
modeling
► Fused Deposition Modeling (FDM), produced and
developed by Stratasys, USA.
► FDM uses a heating chamber to liquefy polymer that is
fed into the system as a filament.
► The filament is pushed into the chamber by a tractor
wheel arrangement and it is this pushing that generates
the extrusion pressure.
► The major strength of FDM is in the range of materials
and the effective mechanical properties of resulting parts
made using this technology.
► Parts made using FDM are amongst the strongest for
any polymerbased additive manufacturing process.
Fused deposition modeling
contd.
Materials for FDM

► The most popular material is the ABSplus material, which

can be used on all current Stratasys FDM machines.
► Some machines also have an option for ABS blended
with Polycarbonate.
Materials for FDM contd.

► Note that FDM works best with polymers that are

amorphous in nature rather than the highly crystalline
polymers.
► This is because the polymers that work best are those that
are extruded in a viscous paste rather than in a lower
viscosity form.
► As in amorphous polymers, there is no distinct melting point
and the material increasingly softens and viscosity lowers
with increasing temperature.
► The viscosity at which these amorphous polymers can be
extruded under pressure is high enough that their shape will
be largely maintained after extrusion, maintaining the
extrusion shape and enabling them to solidify quickly and
easily.
Limitations of FDM

► Sharp features or corners not possible to get;

► Part strength is weak perpendicular to build axis;
► More area in slices requires longer build times;
► Temperature fluctuations during production could lead
to delamination
FDM 3D Printing Product
Selective Laser Sintering
Selective Laser Sintering
contd.
► Layer thickness: nearly 0.1 mm thick;
► The part building takes place inside an enclosed chamber
filled with nitrogen gas to minimize oxidation and
degradation of the powdered material;
► The powder in the building platform is maintained at an
elevated temperature just below the melting point
and/or glass transition temperature of the powdered
material;
► Infrared heaters are used to maintain an elevated
temperature around the part being formed;
► A focused CO2 laser beam is moved on the bed in such a
way that it thermally fuses the material to form the slice
cross-section;
► Surrounding powders remain loose and serve as support
for subsequent layers.
Advantages vs. disadvantages of
SLS
► Advantages
1) A distinct advantage of the SLS process is that because it
is fully self-supporting
2) Parts possess high strength and stiffness
3) Good chemical resistance
4) Various finishing possibilities (e.g., metallization, stove
enameling, vibratory grinding, tub coloring, bonding, powder,
coating, flocking) 5) Complex parts with interior
components, channels, can be built without trapping the
material inside.
6) Fastest additive manufacturing process
► Disadvantages
SLS printed parts have surface porosity. Such porosity can
be sealed by applying sealant such as cyanoacrylate.
SLS 3D Printing Product
Introduction to Reverse
Engineering

► It is the processes of extracting knowledge or design

information from anything man-made and reproducing it
or reproducing anything based on the extracted
information.
► The process often involves disassembling something (a
mechanical device, electronic component, computer
program, or biological, chemical, or organic matter) and
analyzing its components and workings in detail.
► Product of World War II.
Motivation for Reverse
Engineering
► Interfacing: Reverse engineering can be used when a system
is required to interface to another system.
► Military or commercial espionage: Learning about
an enemy’s or competitor’s latest research by stealing
or capturing a prototype and dismantling it.
► Product security analysis: To examine how a product
works, what are specifications of its components,
estimate costs and identify potential patent
infringement.
► Academic/learning purposes: Reverse engineering for
learning purposes may be to understand the key issues of
an unsuccessful design and subsequently improve the
design.
► Saving money: when one finds out what a piece of
electronics is capable of, it can spare a user from purchase
of a separate product.
Reverse Engineering
Process
► Prediction
What is the purpose of this
product? How does it work?
► Observation
How do you think it works?
How does it meet design objectives
(overall)?
► Disassemble
How does it work?
How is it made?
How many parts
and moving
parts?
► Analyze
Carefully examine and analyze subsystems (i.e. structural,
mechanical, and electrical) and develop annotated sketches
Reverse Engineering Process
contd.
► Test
Carefully reassemble the product.
Operate the device and record observations about its
performance in terms of functionality (operational
and ergonomic) and projected durability.
► Documentation
Inferred design goals
Inferred constraints
Design (functionality, form (geometry), and
materials) Schematic diagrams
Lists (materials, components, critical components, flaws,
successes, etc.)
Identify any refinements that might enhance the
products usefulness.
Upgrades and changes
Reverse Engineering Process
contd.
Example of Reverse
Engineering
...........

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