Additive Manufacturing Seminar Report 2017-18

ABSTRACT

Additive manufacturing technologies enable layer-wise fabrication of complex parts

directly from CAD files without part specific tooling Examples of additive
manufacturing technologies include stereo lithography, fused deposition modelling, 3D
printing, selective laser melting, laser engineered net shape processes, ultrasonic
consolidation and selective laser sintering for example fabricates parts in a layer-wise manner by
selectively fusing powdered material in regions defined by the part's cross-sectional geometry.
Additive manufacturing offers many strategic advantages, including increased design freedom for
building complex internal and external part geometries that cannot be made in any other way, the
ability to rapidly literate through design permutations the ability to build functional parts in small lot
sizes for end-user customization or bridge manufacturing and the ability to repair expensive
parts for aerospace and other industries

Additive manufacturing is a technology rapidly expanding on a number of industrial sectors. It

transforms essentially design files to fully functional products. However, it is still hampered by low
productivity, poor quality and uncertainty of final part mechanical properties. The root cause of
undesired effects lies in the control aspects of the process. Optimization is difficult due to limited
modelling approaches. Physical phenomena associated with additive manufacturing processes are
complex, including melting /solidification and vaporization, heat and mass transfer etc.

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TABLE OF CONTENT

Page No...

 ACKNOWLEDGEMENT
 ABSTRACT 1
 TABLE OF CONTENTS 2
 LIST OF FIGURES 3
I. INTRODUCTION 4
II. HISTORY OF ADDITIVE MANUFACTURING 5
III. WHAT IS ADDITIVE MANUFACTURING ? 7
IV. SUBTRACTIVE MANUFACTURING 8
V. DIFFERENCE BETWEEN AM AND SM 9
VI. GENERAL PRINCIPLES 10
VII. AM TECHNOLOGIES AND THEIR BASE MATERIALS 12
VIII. TYPES OF AM TECHNOLOGIES 13
IX. ADVANTAGES 19
X. DISADVANTAGES 20
XI. APPLICATIONS OF AM 21
XII. FUTURE OF AM 24
XIII. CONCLUSION 25
XIV. REFERENCE 26

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LIST OF FIGURES

FIGURE NO. PAGE NO.

1. CHARLES HULL 5
2. ADDITIVE MANUFACTURING 7
3. SUBTRACTIVE MANUFACTURING 8
4. DIFFRENCE BETWEEN AM&SM 9
5. GENERAL AM PROCESS 11
6. SELECTIVE LASER SINTERING (SLS) 13
7. SLS SAMPLES 13
8. 3D PRINTING (3DP) 14
9. 3DP SAMLES 14
10. FUSED DEPOSITION MODELING (FDM) 15
11. FDM SAMPLES 16
12. LAMINATED OBJETIVE MANUFACTURING (LOM) 17
13. LOM SAMPLES 17
14. STEREOLITHOGRAPHY (SLA) 18
15. SLA SAMPLES 18
16. ARCHITECTURAL ENGINEERING CONSTRUCTION 21
17. AUTOMOTIVE 22
18. MEDICAL PROCEDURES 23

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CHAPTER 1
INTRODUCTION

The ASTM F42 Technical Committee defines additive manufacturing(AM) as the “process of
joining materials to make objects from three-dimensional (3D) model data, usually layer upon layer,
as opposed to subtractive manufacturing methodologies”. It is also known as additive fabrication,
additive processes, direct digital manufacturing, rapid prototyping, rapid manufacturing, layer
manufacturing and solid freeform fabrication. The term AM describes additive fabrication processes
in the broadest way that includes AM of prototypes (for design verification, form and fit checking),
tools, patterns, and concept parts, as well as functional parts with required properties for direct
industrial applications and services. Since the late 1980s, AM processes have been investigated, and
some have been developed commercially. They include, among others, Stereolithography (SLA),
Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS), Laminated Objective
Manufacturing (LOM), Three Dimensional Printing (3DP), and Laser Metal Deposition (LMD).
Using AM technology, three dimensional parts are fabricated directly from CAD models and
built in a layer-by-layer manner. AM technology allows freeform fabrication of geometrically
complex parts without special fixtures as required in material removal processes. AM processes
significantly shorten the lead time, are cost-effective for single parts and small batches, and can build
parts not possible with subtractive manufacturing processes . Over the past 20+ years, the research
community has developed novel AM processes and applied them in the aerospace, automotive,
biomedical and other fields (e.g., digital art and architectural design).. Popular applications of these
techniques in the early phases included visual aids, form evaluation, fit assessment, etc. After
intensive research and development in the areas of materials, processes, software and equipment,
rapid tooling applications have been developed by directly or indirectly employing AM technology in
the fabrication of tools, dies and molds. AM also has been used to produce prototype parts with
desired material properties for evaluation and testing, as well as to manufacture small or medium
quantities of end-use products. Currently, the direct fabrication of functional end-use products has
become the main trend of AM technology.

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CHAPTER 2
HISTORY OF ADDITIVE MANUFACTURING

History of additive manufacturing started in the 1980s in Japan. Stereolithography was

invented first in 1983. After that tens of other techniques were invented under the common name
3D printing by Charles Hull (fig.No.1). When stereolithography was invented rapid prototyping
did not exists. Tree years later new technique was invented: selective laser sintering (SLS). First
commercial SLS was in 1990. At the end of 20th century, first bio-printer was developed. Using
bio materials, first kidney was 3D printed. Ten years later, first 3D Printer in the kit was launched
to the market. Today we have large scale printers that printed large 3D objects such are cars. 3D
printing will be used for printing everything everywhere. List of pros and cons questions rising
every day.

CHARLES HULL ( Fig No.1)

AM processes for metal sintering or melting usually went by their own individual names in
the 1980s and 1990s. Nearly all metalworking production at the time was by casting, fabrication,
stamping, and machining; even though plenty of automation was applied to those technologies (such
as by robot welding and CNC), the idea of a tool or head moving through a 3D work envelope
transforming a mass of raw material into a desired shape layer by layer was associated by most people
only with processes that removed metal (rather than adding it), such as CNC milling, CNC EDM, and
many others. As the various additive process. matured and it became clear that soon metal removal
would no longer be the sole occupant of the aforementioned paradigm. It was during this decade that
the term subtractive manufacturing appeared for the large family of machining processes with metal

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removal as their common theme. However, at the time, the term 3D printing still referred only to the
polymer technologies in most minds, and the term AM was likelier to be used in metalworking
contexts than among polymer/inkjet/stereo lithography enthusiasts.
By the early 2010s, the terms 3D printing and additive manufacturing developed senses in
which they were synonymous umbrella terms for all AM technologies. Although this was a departure
from their earlier technically narrower senses, it reflects the simple fact that the technologies all share
the common theme of sequential-layer material addition/joining throughout a 3D work envelope
under automated control. (Other terms that have appeared, which are usually used as AM synonyms
have been desktop manufacturing, rapid manufacturing [as the logical production-level successor to
rapid prototyping], and on-demand manufacturing [which echoes on-demand printing in the 2D sense
of printing].) The 2010s were the first decade in which metal parts such as engine brackets and large
nuts would be grown (either before or instead of machining) in job production rather than obligatory
being machined from bar stock or plate. The term subtractive has not replaced the term machining,
instead complementing it when a term that covers any removal method is needed.

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CHAPTER 3

WHAT IS ADDITIVE MANUFACTURING (AM) ?

Additive Manufacturing (AM) is an appropriate name to describe the technologies that build 3D
objects by adding layer-upon-layer of material, whether the material is plastic, metal, concrete or one
day…..human tissue.

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 as shown in fig.2.

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 (Fig No. 2)

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CHAPTER 4
SUBTRACTIVE MANUFACTURING (SM)

Subtractive manufacturing is a process by which 3D objects are constructed by successively

cutting material away from a solid block of material. Subtractive manufacturing can be done by manually
cutting the material but is most typically done with a CNC Machine as shown in fig.3. Advanced CNC
machines utilize multiple tools and cut around at least three (x, y, and z) axes such that they minimize the
requirement for designers to flip the block. One of the principal advantages to subtractive manufacturing
is the ability to machine an extremely thin piece of plastic into a living hinge. This kind of process is
simply not yet possible in a 3D printer. For those prototypes that require living hinge components it is
useful to produce certain parts using additive manufacturing while using the CNC machine for specialty
components like a living hinge.

Subtractive Manufacturing (Fig No. 3)

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CHAPTER 5

DIFFERENCES BETWEEN AM AND SM

 Traditional manufacturing process creates objects by taking away materials

 AM recreates an object layer by layer from scratch by adding materials .

ADDITIVE MANUFACTURING SUBTRACTIVE MANUFACTURING

Additive manufacturing Already surmised, additive

Subtractive manufacturing Subtractive
manufacturing creates something by manufacturing relies upon the removal of material to create
adding material to the object something
Highly efficient and economical It's inefficient and uneconomical

No wastage. Requires extra machinery and results in a huge

amount of wastage
Creating a form Uncovering a form

Difference between AM & SM (Fig No. 4)

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CHAPTER 6

GENERAL PRINCIPLES

1. Modeling:

3D printable models may be created with a computer aided design package or via 3D scanner.The
manual modelling process of preparing geometric data for 3D computer graphics is similar to plastic
arts such as sculpting. 3D scanning is a process of analyzing and collecting digital data on the shape
and appearance of a real object. Based on this data, three dimensional models of the scanned object
can then be produced.
Both manual and automatic creation of 3D printable models is difficult for average consumers.
This is why several marketplaces have emerged over the last years. Among the most popular are
Shape ways, Thing verse, My Mini Factory and Threading

2. Printing:

Before printing a 3D model from an STL file, it must first be processed by a piece of
software called a "slicer" which converts the model into a series of thin layers and produces a G-
code file containing instructions tailored to a specific printer. Several open source slicer program
exist, including Skeinforge, Slic3r, KISSlicer, and Cura.
The 3D printer follows the G-code instructions to lay down successive layers of liquid,
powder paper or sheet material to build the model from a series of cross sections. These layers,
which correspond to the virtual cross sections from the CAD model, are joined or automatically
fused to create the final shape. The primary advantage of this technique is its ability to create
almost any shape or geometric feature.
Construction of a model with contemporary methods can take anywhere from several hours
to several days, depending on the method used and the size and complexity of the model. Additive
systems can typically reduce this time to a few hours, although it varies widely depending on the
type of machine used and the size and number of models being produced simultaneously.
Traditional techniques like injection moldings can be less expensive for manufacturing
polymer products in high quantities, but additive manufacturing can be faster, more flexible and less
expensive when producing relatively small quantities of parts. 3D printers give designers and

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concept development teams the ability to produce parts and concept models using a desktop size
printer.

3. Finishing:

Though the printer-produced resolution is sufficient for many applications, printing a slightly
oversized version of the desired object in standard resolution and then removing material with
higher-resolution subtractive process can achieve greater precision.
Some additive manufacturing techniques are capable of using multiple materials in the course
of constructing parts. Some are able to print in multiple colors and color combinations
simultaneously. Some also utilise supports when building. Supports are removable or dissolvable
upon completion of the print, and are used to support overhanging features during construction.

General AM Process (Fig No. 5)

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CHAPTER 7

AM TECHNOLOGIES AND THEIR BASE MATERIALS

 There are some main types of additive manufacturing with their type of material and base
materials used in production. they are:

Technologies Type Materials

3D Printing Powder ABS, PLA,

Plastic Resins, etc
Fused Deposition Modeling Extrusion Thermoplastics (PLA ABS),
(FDM) HDPE, Edible material
Rubber, Modelling clay,
silicone, Metal clay, etc
Selective Laser sintering Granular Thermo plastics,
(SLS) Metal powders, ceramic powders
Laminated object Laminated Paper, Metal foil, Plastic film
manufacturing(LOM)

Stereo lithography (SL) Light polymerized Photo polymer

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CHAPTER 8

TYPES OF AM TECHNOLOGIES

 SELECTIVE LASER SINTERING (SLS)

 3D PRINTING (3DP)
 FUSED DEPOSITION MODELLING (FDM)
 LAMINATED OBJECT MODELLING (LOM)
 STEREOLITHOGRAPHY (SLA)

 SELECTIVE LASER SINTERING (SLS):

This is an additive manufacturing technique that uses a high power laserto fuse small
particles of plastic, metal, ceramic or glass powder into the desired 3-D shape.

The laser selectively fuses the material by scanning cross sections generated from a 3-D
digital description of the part, for example a CAD file.

It can be used for both thermoplastics and metal Powder is fed into continuous layer. Laser
is used to fuse sinter powder particles layer-by-layer produces functional parts. Layer thickness
0.004" or less.

SLS ( Fig No. 6) SLS SAMPLES (Fig No. 7)

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 3D PRINTING (3DP) :

3D Printing (Fig No. 8)

 Layer of powder is first spread across build area
 Inkjet-like printing of binder over the part cross-section
 Repetition of the process with the next layer
 Can produce multi-coloured parts
 Useful only for presentation media
 Lowest resolution of all technique
 Market Leader: Z-Corp

3D Printing samples (Fig No. 9)

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 FUSED DEPOSITION MODELLING (FDM):

FDM works on an "additive" principle by laying down material in layers. A

plastic filament or metal wire is unwound from a coil and supplies
material to an extrusion nozzle. The nozzle is heated to melt the material
and can be moved horizontally and vertically. The part, or model, is
produced by extruding mall beads of thermoplastic material to form layers
and the material hardens immediately after extrusion from the nozzle.

 Extruder on a Cartesian robot

 Extruded thermoplastic polymers
 Moderately fast and inexpensive
 Stratasys is the market leader
 Functional parts, ABS and nylon
 Best choice for mechanical engineers and product
developers
 Can be used for direct digital manufacturing

FDM (Fig No. 10)

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FDM Samples (Fig No. 11)

 LAMINATED OBJECT MODELLING (LOM):

In some printers, paper can be used as the build material, resulting in lower cost
to print. During the 1990s some companies marketed printers that cut Cross sections out of
special adhesive coated paper using a carbon dioxide laser and then laminated them together. In
2005 Moor Technologies Ltd developed different process using ordinary sheets of office paper, a
tungsten carbide blade to cut the shape, and selective deposition of adhesive and pressure to bond
the prototype. There are also a number of companies selling printers that print
laminated objects using thin plastic and metal sheets.

 Object made by deposition and cutting of layers of tapes

 Introduced in 1991 by Helisys Inc of Torrance.
 Cubic and Helisys offer this technology
 Slow, sharp edges
 Research on composites prepregnated moldless manufacturing
 Inexpensive depending on accuracy, large scale models possible

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 Slow and inaccurate (knives vs lasers)

Fig No. 12

LOM Samples (Fig No. 13)

 STEREOLITHOGRAPHY (SLA):

Stereolithographyisaprocessforcreatingthree-dimensionalobjects
using a computer-controlledlasertobuildtherequired structure, layerbylayer. It does this by
using a resin known as liquid photopolymer that hardens when in contact with the air.

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 Patented in 1986
 3D System is the market leader
 Highest resolution and smoothness
 UV Laser beam cure cross-sections of parts in a liquid batch of photo reactive resin
 Sub Variants: DLP entire layer projection

Stereolithography (Fig No. 14)

SLA Samples (Fig No. 15)

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CHAPTER 9

ADVANTAGES OF AM

 Adopted 3D printing as a way to increase innovation.

 Mechanical properties of products are more as compared to that which are made by
conventional process.
 Reduce costs and speed up the process.
 3D models of buildings can be easily created and edited as plans develop something that
used to take a significant amount of time to make.
 Freedom of creation of more complex geometries.
 More Complex Geometries
• Internal Features & Structures
• Parts Consolidation
 Enables business models used for 2D printing, such as for photographs, to be applied to
physical components
 The unattainable triangle of speed, price and quality
 Eliminates drivers to concentrate production
 "Design Anywhere Manufacture Anywhere" is now possible
 Manufacture at the point of need rather than at lowest labor location

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CHAPTER 10

DISADVANTAGES OF AM

 Construction of large parts is not possible but research are going to make large machines.
 Machine cost is high
 The current slow print speed of 3D printers limits their use for mass production
 Limited number of materials
 Requires post-processing
 Poor mechanical properties

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CHAPTER 11

APPLICATIONS OF ADDITIVE MANUFACTURING

 Medical procedures
 Advances in research
 Product prototyping
 Historic Preservation
 Architectural Engineering Construction
 Advanced Manufacturing
 Food Industries
 Automotive
 Accessories

 Architectural Engineering Construction

Architectural Engineering Construction E.g. (Fig No. 16)

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 Automotive

Automotive E.g. ( Fig No. 17)

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 Medical Procedures

Medical Procedure E.g. (Fig No.18)

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CHAPTER 12

FUTURE OF ADDITIVE MANUFACTURING

 Future applications for Additive Manufacturing might include:

 creating open-source scientific equipment to create open source labs.
 Science-based applications like reconstructing fossils in paleontology.
 Replicating ancient and priceless artifacts in archaeology.
 Reconstructing bones and body parts in forensic pathology.
 Reconstructing heavily damaged evidence acquired from crime scene investigations.
 The technology currently being researched for building construction.

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CHAPTER 13

CONCLUSION

Additive manufacturing Technologies could revolutionize and re-shape the world. Advances in AM
technology can significantly change and improve the way we manufacture products and produce
goods worldwide.

If the last industrial revolution brought us mass production and the advent of economies of scale - the
digital 3D printing revolution could bring mass manufacturing back a full circle - to an era of mass
personalization, and a return to individual craftsmanship.

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REFERENCE

1. http://www.thethirdindustrialrevolution.com/

2. http://www.additivemanufacturing.com/

3. http://www.linkedin.com/pulse/

4. C. Iancu, D. Iancu, and A. Stamcioiu, “From Cad model to 3D print via

”STL” file format,” http://www.utgjiu.ro/rev mec/mecanica/pdf/2010-01/13
Catalin%20Iancu.pdf.

5. T. Wohlers, “Making products by using additive manufacturing,”

Manufacturing Engineering, vol. 146, no. 4, pp. 70–74, 2011.

6. T. Wohlers, “Additive Manufacturing Advances,” Manufacturing

Engineering, vol. 148, no. 4, pp. 55–56, 2012.

7. I. Gibson, T. Kvan, and W. Ling, “Rapid prototyping for architectural

models,” Rapid Prototyping Journal, vol. 8, no. 2, pp. 91–99, 2002.

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