ME 468

ADDITIVE MANUFACTUIRNG
• Text Books
• 1. Gibson, I, Rosen, D W., and Stucker,B., Additive Manufacturing
Methodologies: Rapid Prototyping to Direct Digital
Manufacturing,Springer, 2010
• 2. Chua C.K., Leong K.F., and Lim C.S., “Rapid prototyping:
Principles and applications”, Third Edition, World Scientific
Publishers, 2010
• 3. Chee Kai Chua, Kah Fai Leong, 3D Printing and Additive
Manufacturing: Principles and Applications: Fourth Edition of
Rapid Prototyping, World Scientific Publishers, 2014
• 4. Gebhardt A., “Rapid prototyping”, Hanser Gardener
Publications, 2003
 Mod 1 Syllabus
Introduction to Additive manufacturing:
Importance of Additive Manufacturing- Basic
principle of additive manufacturing- Procedure
of product development in additive
manufacturing. Classification of additive
manufacturing processes, Materials used in
additive manufacturing- Benefits &
Challenges in Additive Manufacturing.
 Introduction
• The term Rapid Prototyping (or RP) is used in a variety of
industries to describe a process for rapidly creating a
system or part representation before final release or
commercialization
• Users of RP technology have come to realize that this term
is inadequate and does not effectively describe more recent
applications of the technology. Improvements in the quality
of the output from these machines have meant that there
is a much closer link to the final product
• ASTM standards now use the term Additive Manufacturing.
• The basic principle of this
technology is that a model, initially
generated using a three-
dimensional Computer Aided
Design (3D CAD) system, can be
fabricated directly
• The key to how AM works is that
parts are made by adding material
in layers; each layer is a thin cross-
section of the part derived from the
original CAD data.
• Can be made of plastics, metal
powder, ceramic powder and paper
POCEDURE OF PODUCT DEVELOPMENT
The Generic AM Process
Step 1:Conceptualization and CAD
• All AM parts must start from a software model that fully
describes the external geometry. Reverse engineering
equipment (e.g., laser scanning) can also be used to
create this representation. Initially, this was the principle
surrounding CNC machining technology in general
• Eg CATIA,CREO, FREECAD,SOLID WORKS
Step 2: Conversion to STL

• Nearly every AM technology uses the STL file format. The term STL was
derived from STereoLithograhy, which was the first commercial AM
technology from 3D Systems in the 1990s
• approximating the surfaces of the model with a series of triangular
facets
• The minimum size of these triangles can be set within most CAD
software and the objective is to ensure the models created do not
show any obvious triangles on the surface
• The process of converting to STL is automatic within most CAD
systems, but there is a possibility of errors occurring during this phase
• STL file repair software, like the MAGICS software from the Belgian
company Materialise, is used when there are problems with the file
generated by the CAD system that may prevent the part from being
built correctly.
Step 3: Transfer to AM Machine and STL File
Manipulation
• The user may wish to reposition the part or even change
the orientation to allow it to be built at a specific location
within the machine. It is quite common to build more
than one part in an AM machine at a time.
• STL files can be linearly scaled quite easily. Some
applications may require the AM part to be slightly larger
or slightly smaller than the original to account for
process shrinkage or coatings; and so scaling may be
required prior to building
Step 4: Machine Setup
• setup parameters, layer thickness, variety of materials etc. It is
common in the more complex cases to have default settings or save
files from previously defined setups to help speed up the machine
setup process and to prevent mistakes being made. Normally, an
incorrect setup procedure will still result in a part being built. The
final quality of that part may, however, be unacceptable.

Step 5: Build
• layer-based manufacturing takes place
• All AM machines will have a similar sequence of layer control, using
a height adjustable platform, material deposition, and layer cross-
section formation
• All machines will repeat the process until either the build is
complete or there is no source material remaining
Step 6: Removal and Cleanup
• part must be either separated from a build platform on which the part
was produced or removed from excess build material surrounding the
part
• Some AM processes use additional material other than that used to
make the part itself (secondary support materials)
Step 7: Post-process
• Post-processing refers to the (usually manual) stages of finishing the
parts for application purposes. This may involve abrasive finishing, like
polishing and sandpapering, or application of coatings.
• Different AM processes have different results in terms of accuracy and
material properties. Some processes produce relatively fragile
components that may require the use of infiltration and/or surface
coatings to strengthen the final part
Step 8: Application
• although parts may be made from similar
materials to those available from other
manufacturing processes (like molding and
casting), parts may not behave according to
standard material specifications
• Some AM processes inherently create parts with
small voids or bubbles trapped inside them
• Some AM processes inherently create parts with
small voids or bubbles trapped inside them
 Classification of AM Processes
• classify according to baseline technology, like
whether the process uses lasers, extrusion
technology
• according to the type of raw material input
Material extrusion
•  uses a plastic filament or metal wire
that is wound on a coil and unreeled
to supply material to an extrusion
nozzle. The nozzle heats to melt the
material and can be moved in both
horizontal and vertical directions

Photopolymerisation
• liquid polymer is exposed to light. The
exposed liquid polymer hardens. The
build plate then moves down in small
increments and the liquid polymer is
again exposed to light. The process
repeats until the model has been built
Sheet lamination
•  paper can be used as the build
material
Powder bed fusion
• The technique fuses parts of the
layer, and then moves the working
area downwards, adding another
layer of granules and repeating the
process until the piece has built up.
This process uses the unfused media
to support overhangs
Binder jetting
• Similar to document printer
• the binder jetting process selectively jets adhesive
onto a bed of powder
• The binder jetting machine will selectively bind
(glue) one layer of powder at a time, each
succeeding layer being swept over the previous
one
Material jetting
•  material jetting can selectively place a number of
materials in different parts of the model as well as
blend these photopolymers to create composites
Directed Energy Deposition
• most often used to add material to existing parts
•  melted by a focused energy source generally
resulting in a melt pool. As the melt pool is moved
around (“directed”) the wake of molten material
left behind quickly solidifies as added material
• Similar to welding
• Carbon fibre
• Nitinol
• Graphene