Chapter 2

Families of Additive Manufacturing

 Contents

1. Introduction – Additive Manufacturing

2. Powder Bed Fusion Technology
3. Material Extrusion
4. Directed Energy Deposition
5. Binder Jetting
6. Material Jetting
7. Vat Photopolymerization
8. Sheet lamination
9. Conclusion
10. Questions and Discussion
1. Introduction – Additive Manufacturing

Processes
❖ Need for Standardization:

• We define Additive Manufacturing (AM) as a layer-by-layer fabrication of 3-

diamensional objects.

• There are lots of AM technologies evolving in the market currently → have

different production techniques, strength, and material used.

• To standardize the Additive Manufacturing process, the ASTM group – “ASTM

F42 – Additive Manufacturing’ – has categorized the AM processes into seven
types.
Additive Principle Material
Manufacturing
Technology

1. Powder Bed Fusion • It utilizes heat source Metal, Plastic, and

(laser/electron beam) or Ceramic
binding agent to cause
fusion or binding
between layers.

2. Material Extrusion • Material is selectively Metal, Composite

dispenses through a and Plastic
nozzle or orifice.
Additive Principle Material
Manufacturing
Technology

3. Directed Energy • Focused thermal Energy Metal

Deposition is used to fuse materials
as they are being
deposited.

4. Binder Jetting • A liquid bonding agent Metal, Ceramic,

selectively binds regions Sand, Glass, and
of a powder bed. Plastic
Additive Principle Material
Manufacturing
Technology

5. Material Jetting • Droplets of material are Metal, Plastic, and

selectively deposited Wax
and cured on a build
plate.

6. Vat • A liquid photopolymer in Plastic

Photopolymerization a vat is selectively cured
by light-activated
polymerization.
Additive Principle Material
Manufacturing
Technology

7. Sheet Lamination • Focused thermal energy Sheet Metal,

is used to fuse materials Composite, and
by melting as they are Paper
being deposited.
 Additive Manufacturing is playing very crucial role!

(Binder (Laser
Melting)
Jetting
) (Electron Beam
Melting)

(Laser Sintering)
(Stereo (PolyJet) (Fused
Lithography ) Deposition
Melting) (Multi-Jet)

• We will talk about this again at the end of this chapter!

(Source: additively.com)
2. Powder Bed

Fusion
• Definition:

It is a process whereby a heat source (laser, electron beam, or thermal energy) is

used to consolidate material in a powder form to form three-dimensional object.

• Vide
o
• Sub-type of powder bed fusion:
• Basic Steps:

1. Process consists of the spreading of powder material over the bed or previous
powder layer.
2. the heat source (laser/electron beam) or fusing agent is used to cause the fusion/
binding between the layers.
3. Melting and subsequent solidification during process will result in welding of new
layer with the previous layer.
4. Platform lowers by same layer thickness. New powder layer gets deposited over
the previous one.
5. Same process repeats until the complete part is printed.
• Basic information related to four types:
• Advantages:
1. The PBF technology uses a large range of material, such as ceramic, plastic, and
metals, to print the 3D parts.
2. These parts have shown mechanical properties much better (or least comparable) to
that of conventional manufactured parts.
3. The PBF technology offer various advantages such as design freedom, material
freedom, buy to fly ratio equal to 1, better mechanical properties.
4. This process is often considered to be best choice for prototype parts. However, things
are changing very rapidly in AM industry.

• Disadvantages:
1. This technology has slow operational speed and limited to the size of the parts.
2. While printing the parts, the process engineer needs to consider shrinkage factor.
3. There are serious challenges associated with the powder handling and disposal. (But,
as we mentioned in last paragraphs that the things are changing very rapidly, there are
new, modified machines are available where above limitations are resolved to very
great extents.)
3. Material

Extrusion
• Definition:

The Material Extrusion is a rapid prototyping and manufacturing techniques where the
material (plastic filament) is extruded though the heated nozzle in tracks or beads on the
build surface layer by layer to construct the 3D parts as shown in Figure.

Schematic representation of Fused Deposition

Modeling technology. (Source: Engineering Product
Design)

• Vide
o
• Advantages:
1. Process is inexpensive and economical due to its low initial and running cost.
2. The process can be installed in the office environment and in small space.
3. Selection of material is wide
4. Allow multiple color of material to print
5. Easily understandable print techniques
6. No supervision is required.
7. Parts have good structural properties

• Disadvantages:
1. Accuracy of the print is limited to the nozzle diameter
2. Accuracy and speed are low compared to the other AM technologies
3. Visible layer lines
4. Toxic print material
5. Support may required
6. Delamination can be seen
4. Directed Energy

Deposition
• Definition:

The Material Extrusion is a rapid prototyping and manufacturing techniques where the
material (plastic filament) is extruded though the heated nozzle in tracks or beads on the
build surface layer by layer to construct the 3D parts as shown in Figure.

Schematic representation of Directed Energy

Deposition technology. (Source: Bits into Atoms:
3D Printing and Design)

• Vide
o
• Basic Steps:

1. The object for repair/maintenance will be fixed on to the platform below nozzles.
2. The material (either in the form of wire or powder) coming out the nozzle will get
melted with the energy source. The nozzle deposits the melted material on surface of
the object where it then cools and solidifies.
3. Material is added layer by layer till work is completed.

✔ Important Information related to Directed Energy Deposition:

• This process has various terminologies such as Laser Engineering Net Shaping (LENS), Laser
Metal Deposition (LMD), Direct Metal Deposition (DMD), 3D Laser Cladding.
• The process was investigated by Sandia National Laboratories in 1995 and given a name LENS.

• Further, this process was commercialized by Optomec design Company.

• Advantages:

(1) Process is not limited by directions or axis

(2) Highest single point deposition is possible
(3) Effective for adding new features to the existing part
(4) Multiple material in single part is possible
(5) Ability to control the microstructure to the high degree and therefore high quality
functional parts

• Disadvantages:

(1) Post processing is compulsory required to get the finished part.

(2) Limited material use.
(3) This process required further research for the further advancement to use other
material and get the required part quality.
5. Binder

Jetting
• Definition:

This technology consists of selective application of the liquid binding agent on to the
powder material (metal/ceramic/plastic) layer-after-layer to form a 3D part. Unlike
powder bed fusion, in Binder Jetting technology, heat is not applied during the process.

Fig. 5 Representative image showing deposition of liquid

binding agent to join the powder particles. (Source: ExOne)

• Vide
o
• Basic Steps:
1. Powder material is deposited evenly on the build platforms using roller,
2. Print head selectively applies the liquid binding agent over the powder layer as shown
in Fig. 5,
3. The build platform moves down by same layer thickness,
4. Then, new powder layer will get deposited over the previous powder layer followed by
selective application of liquid binder,
5. Process repeats till part is completed; and
6. After removal of 3D Printed part, post-processing is often necessary to make the
stronger and to give better mechanical and structural properties.

Steps involved in Binder Jetting technology: (a) printing of part where object
will be in green state, (b) sintering to get the strength and density, and finally
(c) final object in brown state.
• Advantages:

1. This technology uses metal, ceramic, and plastic powder. Since it uses liquid binder,
process is cost-effective and gives advantages such as:
2. It allows us to create the full color printing;
3. Support structure is not required (part is self-supported),
4. It uses range of material: metals, ceramic, and polymer; and
5. Process gives relatively high turnover manufacturing method.

• Disadvantages:

(1) Additional post-processing is required to improve the mechanical properties and make
the part suitable for structural application; and
(2) Printed parts from this technology are not always suitable for structural application.
6. Material

Jetting
• Definition:

Material Jetting technology consists of selective jetting of droplets of material layer after
layer to build 3D printed part. The build materials are required to be liquid form in order
to deposit in the form of droplets. This process is also known by Polyjet, Multi-Jet
Modelling, Smooth Curvature Printing, Projet.

Representative image for Polyjet

technology. (Source:AdditiveBlog)
• Vide
o
• Basic Steps:

(1) Similar to other AM processes, first CAD data file is sliced into layers and file is sent to
the machine;
(2) Droplets of material are selectively jetted on the build platforms and cured
simultaneously using UV lights;
(3) Build platform moves down by same layer thickness;
(4) Material is jetted and cured again on the previous layer. The process continues until
job is finished;
(5) Support structure can be added is required; and
(6) Once part is completed, the parts will be taken out from the machine and supports are
removed. Figure shows representative image for Material Jet technology.
• Advantages:
(1) High level accuracy: this is due to the high accuracy maintained while deposition of the
droplets;
(2) Incorporate multiple materials and colors under one process;
(3) High Resolution: this brings delicate features to life; and
(4) Get to the market fast.

• Disadvantages:
(1) Process is limited to only polymer and waxes; and
(2) Support material is required.
7. Vat

Photopolymerization
• Definition:

This process consists of a vat filled with the liquid photopolymer (resin) which selectively
gets hardened by selective exposure of ultraviolet (UV) radiation. When UV radiations
expose on liquid polymer, it initiates polymerization and turns in solid. Alternative names
for this technique are Stereolithiography Apparatus (SLA), Digital Light Processing (DLP),
and Continuous Liquid Interface Procedure (CLIP).

Representative image for Vat Photopolymerization.

• Vide
o
• Basic Steps:

(1) The liquid photopolymer/resin is filled inside the vat. The process starts with moving
down the build platform by one layer thickness in a Vat.
(2) UV radiation is selectively exposed on the resin on the build platform.
(3) Then, the platform moves downwards by one layer thickness to allow the surrounding
liquid resin to deposit on cured polymer. (We can use blade over each layers to make layer
smooth and so no defect within layers.)
(4) Process repeats until part is complete.
(5) After completion, the part can be taken out of the resin.
• Advantages:

(1) High level of accuracy and complexity;

(2) Smooth surface finish (upto nano-scale level);
(3) Relatively quick process; and
(4) Typically large areas: e.g. Object 1000 machine has built volume of 1000 * 800 * 800
mm3 and maximum weight 200 Kg.

• Disadvantages:
(1) More time is required to remove all resin
(2) More time required to remove support structures
(3) Post curing is required to make part strong for structural application
(4) Process limited for UV curable resins
(5) Some resins are toxic
8. Sheet

Lamination
• Definition:

In Sheet Lamination process, material (paper, polymer, or metal) sheets are stacked and
laminated together using adhesive, chemical, brazing, or ultrasonic welding layer after
layer to form a 3D parts. Unneeded parts are cut after layer by layer once two layers are
bound together as shown in Figure.

Representative image for sheet lamination

process
• Basic Steps:

(1) The sheet is first kept on the table/cutting bed;

(2) Next sheet is placed over previous one which can be bound together using adhesive,
chemical, brazing, or welding process;
(3) Unneeded part is removed from the layers by laser or knife;
(4) Next sheet is placed over previous one; and
(5) The process repeats till part is finished.
• Advantages:

(1) Relatively low cost;

(2) Fast process and ease of material handling; and
(3) Dissimilar metal sheets can be can be printed together

• Disadvantages:

(1) Limited material use;

(2) Fusion process required more research; and
(3) Process required post-processing to achieve the desired properties.
9. Summary

(Binder (Laser
Melting)
Jetting
) (Electron Beam
Melting)

(Laser Sintering)
(Stereo (PolyJet) (Fused
Lithography ) Deposition
Melting) (Multi-Jet)

• We will talk about this again at the end of this chapter!

(Source: additively.com)
9. Questions and

Discussion

1. What are the families of AM?

2. What is the difference between Powder Bed Fusion and
Material Extrusion?
3. What are the types of Powder Bed Fusion technology? Explain.
4. What is difference between Material Jetting and Binder Jetting
technologies?