Additive manufacture

(AM)

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Additive Manufacturing:
The terms below are basically synonymous today

Rapid Prototyping (RP)

Solid Freeform Fabrication (SFF)
Free Form Fabrication (FFF)
Rapid Manufacturing (RM)
Rapid Prototyping & Manufacturing (RP&M)
Direct Manufacturing (DM)
Direct Material Deposition (DMD)
Three Dimensional Printing (3DP)
Stereolithography

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 Definitions: Additive
Manufacturing (AM) and Rapid
Prototyping

Additive Manufacturing (AM) Kemajuan teknologi yang

membangun objek 3D dengan menambahkan lapisan-pada-lapisan
material, bahan pembangunnya adalah plastik, logam, beton, dll
Perangkat yang digunakan adalah penggunaan komputer, perangkat
lunak pemodelan 3D (Computer Aided Design atau CAD), peralatan
mesin dan bahan layering. Setelah sketsa CAD diproduksi, peralatan
AM membaca data dari file CAD dan meletakkan turun atau
menambahkan lapisan berturut-turut cairan, bubuk, bahan lembar
atau lainnya, dalam mode layer-on-layer untuk membuat objek 3D.
Istilah AM mencakup banyak teknologi termasuk subset seperti 3D
Printing, Rapid Prototyping (RP), Direct Digital Manufacturing
(DDM), manufaktur berlapis dan fabrikasi aditif.

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History: In the Beginning…

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The Impact of Digital Computing
Power
Previously
 Today


Years in Design  Months in Design

Design Engineer Completes  CAD Design
design ◦ Flexible
◦ No Longer Flexible
 No Blueprint Required
 Drafting Completes Blueprint ◦ Flexible
◦ No Longer Flexible
Tooling is Made
 No Part Specific Tooling
◦ Flexible
Prototype Is Made

Corrections Made in Actual

Prototype is Quickly Made and


Production Evaluated
Corrections Made Before

Production

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Cost of Change in the
Design-to-Manufacturing
Process
$ 10M
1M
100K

10K
1K

Design Design Process Test Final

Test Planning Production Production

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CAD-STL Relationship
Additive manufacturing has become common in
product development, so it is often necessary to
translate CAD models into a format that RP
machines can process.
The most popular format is the STL file. “STL” is a
derivative of the stereolithography process and was
developed by 3D Systems, Inc. in the 1980s. STL is
now officially an abbreviation for “Standard
Tessellation Language” file format.

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Common CAD Systems:
AutoCAD (Autodesk)
CATIA (Dassault)
I-DEAS Master Series (Structural Dynamics Research
Corporation)
Solid Edge
Pro/ENGINEER (Parametric Technology Corporation)
Unigraphics (EDS)
This list is by no means complete!

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Common Commercial Systems

Stereolithography (STL)
Ink-Jet Printing (3DP)
Fused Deposition Modeling (FDM)
Selective Laser Sintering (SLS)
Laminated Object Manufacturing (LOM)
Laser Engineered Net Shape (LENS)

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 Stereolithography
Example: 3D Systems Inc., Models: SLA 250-7000, Viper
Photopolymer resin cured with ultraviolet laser, floor models
build 10-24” models
Materials: range of epoxy acrylates
Advantages
◦ High accuracy
◦ Smooth upward facing surfaces
◦ Repeatability
Limitations
◦ Same-material support structures require manual processes for removal
◦ Environment issues with handling liquid polymers

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Stereolithography

Courtesy of 3D Systems,
11
Inc.
Stereolithography

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 Fused Deposition Modeling

Materials: Polyester, ABS, polycarbonate, poly-phenyl-sulfone

Advantages:
◦ Operates unattended
◦ Accommodates several users (queue up on network like a printer)
◦ Durable, functional, low cost materials
◦ Capability to build hollow or honeycombed parts

Limitations:
◦ Small size of prototype parts and models
◦ Limited material selection
◦ Low dimensional accuracy/poor surface finish
◦ Slow build speed

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Layer by layer

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Fused Deposition
Modeling

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Selective Laser
Sintering
Example: 3D Systems, Models: Sinterstation 2000-2500,
Vanguard
Thin layers of powder are spread and melted to shape with a
laser; large floor models build 12-15” models
Materials: Polyamide, Glass-Filled Polyamide, Polymer-
coated Steel
Advantages
◦ Selection of strong materials
◦ Good dimensional accuracy
◦ Requires no physical/mechanical supports in part bed for overhangs
Limitations
◦ Expensive build materials
◦ Powder handling can be cumbersome
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Selective Laser
Sintering

Courtesy of 3D Systems,
18
Inc.
Selective Laser Sintering

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Selective Laser Sintering

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Laminated Object
Manufacturing
Example: Cubic Technologies, Model: LOM 1015, 2030
Uses layers of paper bonded together and cut with a laser, floor models
build 15-30” models
Materials - laminated paper
Advantages
◦ Large, dense part build much quicker than most other RP processes
◦ Material is workable and finishes like wood patterns
◦ Woodlike material is familiar for traditional foundry and pattern operations
Limitations
◦ More waste material
◦ Difficult to remove supports from overhangs and cavities
◦ Material delaminates over time

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Laminated Object Manufacturing

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Laminated Object
Manufacturing

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Laminated Object Manufacturing

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Plaster based 3D printing

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