RAPID MANUFACTURING TECHNOLOGIES

Module
Material Extrusion
3&4

- Creation of new system for the benefit of mankind

Dr. M.Sugavaneswaran
Asst. Prof. (Sr.)
SMEC
 Rapid Prototyping/Manufacturing - Introduction

“The fabrication of a physical, three dimensional part of arbitrary shape

directly from a numerical description - typically a Computer Aided Design model, by

a quick, highly automated and totally flexible manufacturing process”

 Material • Material • Forging

addition rapid removal
rapid • Electro/Hydro
prototyping
prototyping forming
 Additive • Drilling
Manufacturing • Powder Metallurgy
• Turning
 Welding • Shaping
 COURSE PLAN

Module Topics Hours

I Introduction to Rapid Manufacturing,: Additive Manufacturing evolution, 4

Additive manufacturing processes and their relationship with subtractive
manufacturing, Advantages of RM. Generalized rapid manufacturing process
chain, Rapid Tooling –Benefits, Applications.
II Data Processing for Rapid Manufacturing: Conceptualization and CAD 4
model preparation, data formats – Conversion to STL file format, Fixing the
STL file, Part orientation, Support structure design, Model Slicing, Direct
and adaptive slicing.
III Rapid Manufacturing Processes, Materials and its application: Sintering, 4
Powder Bed Fusion, extrusion, jetting, Photopolymerization, direct-write, sheet
lamination, directed-energy deposition and the latest state of the art. Multiple
Materials, Hybrids, Composite Materials, current and future directions.
IV Post-Processing: Support material removal, surface texture improvement, 4
accuracy improvement, aesthetic improvement, preparation for use as a pattern,
property enhancements using non-thermal and thermal techniques.

2/8/2017
 COURSE PLAN

Module Topics Hours

V Design for Rapid Manufacturing (DFRM): Core DFAM Concepts and 4

Objectives: Complex Geometry, Customized Geometry, Integrated Assemblies and
Elimination of Conventional design for manufacture (DFM) Constraints. RM
Unique Capabilities, Exploring Design Freedoms and Design Tools for RM.
VI Guidelines for process selection: Introduction, selection methods for a part, 4
challenges of selection, example system for preliminary selection, production
planning and control.
VII Rapid Tooling: Direct tooling & Indirect Tooling methods, Reaction Injection 4
Molding, Wax Injection Molding, Vaccum Casting, RTV Silicone Rubber Molds,
Spin-Casting, Cast Resin Tooling.

VIII Contemporary Discussion 2

2/8/2017
 BOOKS AND
REFERNCES
Text Book

1. Ian Gibson, David W. Rosen, Brent Stucker (2015), Additive Manufacturing

Technologies: Rapid Prototyping to Direct Digital Manufacturing, 2nd Ed.,
Springer Science & Business Media.

Reference Books

2. Dongdong Gu (2014), Laser Additive Manufacturing of High-Performance Materials, ,

Springer Publications.

3. Ali K. Kamrani, Emad Abouel Nasr (2006), Rapid Prototyping: Theory and Practice,
Springer.

4. D.T. Pham, S.S. Dimov (2001), Rapid Manufacturing: The Technologies and
Applications of Rapid Prototyping and Rapid Tooling, Springer.

5. Andreas Gebhardt (2011),Understanding Additive Manufacturing, Hanser Publishers.

2/8/2017
Lecture Schedule

DAY TIME (SLOT) VENUE

For subject discussions/questions/assignments/projects

E-mail: sugavaneswaran.m@vit.ac.in
Room No : MB 133B (M.G.R BLOCK)

Attendance : MINIMUM 75%

2/8/2017
RAPID MANUFACTURING
TECHNIQUES CLASSIFICATION

Vat Photopolymerization
Material Extrusion
Material Jetting
Binder Jetting
Powder Bed Fusion
Directed Energy Deposition
Sheet Lamination

Source: ASTM International Committee F42 on Additive Manufacturing Technologies

9/24/2016 Dr.M.Sugavaneswaran
RAPID MANUFACTURING
TECHNIQUES CLASSIFICATION

Vat Photopolymerization
Material Extrusion
Material Jetting
Binder Jetting
Powder Bed Fusion
Directed Energy Deposition
Sheet Lamination

Source: https://insights.globalspec.com/article
9/24/2016 Dr.M.Sugavaneswaran
RAPID MANUFACTURING
TECHNIQUES CLASSIFICATION

Powder Bed
Fusion

Ref: Rapid Prototyping Process 2015, Available from: http://www.custompartnet.com/wu/selective-

laser-sintering
9/24/2016 Dr.M.Sugavaneswaran
RAPID MANUFACTURING
TECHNIQUES CLASSIFICATION

Binder Jetting

Ref: Rapid Prototyping Process 2015, Available from: http://www.custompartnet.com/wu/

9/24/2016 Dr.M.Sugavaneswaran
RAPID MANUFACTURING
TECHNIQUES CLASSIFICATION

Vat Polymerization

Ref: Rapid Prototyping Process 2015, Available from: http://www.custompartnet.com/wu/

9/24/2016 Dr.M.Sugavaneswaran
RAPID MANUFACTURING
TECHNIQUES CLASSIFICATION

Material jetting

Ref: Rapid Prototyping Process 2015, Available from: http://www.custompartnet.com/wu/

9/24/2016 Dr.M.Sugavaneswaran
RAPID MANUFACTURING
TECHNIQUES CLASSIFICATION

Material Jetting

Ref: Rapid Prototyping Process 2015, Available from: http://www.custompartnet.com/wu/

9/24/2016 Dr.M.Sugavaneswaran
RAPID MANUFACTURING
TECHNIQUES CLASSIFICATION

Material extrusion

Ref: Rapid Prototyping Process 2015, Available from: http://www.custompartnet.com/wu/

9/24/2016 Dr.M.Sugavaneswaran
RAPID MANUFACTURING
TECHNIQUES CLASSIFICATION

Direct Energy Deposition

Ref: Rapid Prototyping Process 2015, Available from: http://www.custompartnet.com/wu/

9/24/2016 Dr.M.Sugavaneswaran
RAPID MANUFACTURING
TECHNIQUES CLASSIFICATION

Sheet Lamination

Ref: Rapid Prototyping Process 2015, Available from: http://www.custompartnet.com/wu/

9/24/2016 Dr.M.Sugavaneswaran
 FUSED DEPOSISTION MODELING

 Principle,
 Details of processes,
 Process variables,
 Types,
 Products,
 Materials and
 Applications.
 FUSED DEPOSISTION MODELING
Working Principle

The FDM process was originally developed by Advanced Ceramics Research

(ACR) in Tucson, Arizona, but the process has been significantly advanced by
Stratasys, Inc. of Minneapolis, Minnesota

Working Principle
FDM utilizes engineering thermoplastics,
which are heated from filament form and
extruded in very fine layers to build each
model from the bottom up.

Filament diameters range from 0.1 mm

to 0.25 mm. The platform moves in z-
direction and defines the layer thickness,
as the material is squeezed on the top of
the partly finished part
 FUSED DEPOSISTION MODELING
Working Principle & Construction
The extrusion-based process utilizes filaments of molten thermoplastic that are
extruded from a heated tip to build up layers comprising the physical model. Figure
shown is a depiction of the head and process in which the material is pulled off the
spool, heated just above the melting temperature, and deposited at the desired
location.
The key steps are
1. Starting with the filament being fed into the drive wheels
2. The drive wheels force the filament into the liquefier
3. The heater block melts the filament
4. The solid filament is used as a linear piston
5. The melted filament is forced out through the tip
 FUSED DEPOSISTION MODELING
Working Principle & Construction
The process needs supports. They are made by a second nozzle that extrudes another
plastic support material simultaneously with the build material.
The simultaneous processing of two materials indicates that the FDM process is
basically capable of handling multi-material print heads.
Therefore, the manufacture of multi- material parts is possible
After deposition, the pasty string (of the build material as well as of the support
material) solidifes by heat transfer into the preceding layer and forms a solid layer.

Then the platform is lowered by the amount of one layer thickness and the next layer is
deposited. The process repeats until the part is completed.
Materials
The models can be made from acrylonitrile butadiene styrene (ABS), polycarbonate,
polyphenylsulfone (PPSF), PolyLactic Acid (PLA), Nylon and various versions of these
materials. Ultem 9085 is a high-performance plastic that can be used in the application
in the rapid prototyping process
 FUSED DEPOSISTION MODELING
Process Parameters
FDM parts show typical surface textures that result from the extrusion process
parameters. According to the layer thickness and the orientation of the part in the
build chamber, these textures are more or less visible.

Therefore, the positioning (orientation) in the build chamber has a big influence on the
appearance of the part. Post processing requires the removal of the supports, which
can be done manually, or using a special washing device.

Some of other important Build Parameters are

Sets

Road Width

Slice thickness

Fill Spacing

Build time
 FUSED DEPOSISTION MODELING
Materials & Methods

Materials and its properties

Source: Ian Gibson· David Rosen Brent Stucker Additive Manufacturing Technologies 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing Second Edition

9/21/2016
 FUSED DEPOSISTION MODELING
Materials & Methods

Source: Additive Manufacturing 3D Printing for Prototyping and Manufacturing- Andreas Gebhardt, Hanser Publications
9/21/2016
 FUSED DEPOSISTION MODELING
Materials & Methods

Source: Additive Manufacturing 3D Printing for Prototyping and Manufacturing- Andreas Gebhardt, Hanser Publications
9/21/2016
 FUSED DEPOSISTION MODELING
Process Parameters

Unprocessed
material

Part quality &

mechanical
properties

9/21/2016
 FUSED DEPOSISTION MODELING
POST PROCESSING
• Supports are necessary for projecting sections and
for the model as a base.
• This need to be removed for end application
• Surface finish of the parts produced by using FDM is
not very good (due to stair step error) as compared
Source: RP-Lab, FH Aachen University of Applied
to wax patterns, which are conventionally used in Science , Stratasys

investment casting.
• In some case, aesthetic finish or texture is required for
FDM parts.
• Therefore, FDM parts required post process to
improve its surface finish

Source: Additive Manufacturing 3D Printing for Prototyping and Manufacturing- Andreas Gebhardt, Hanser Publications

9/24/2016 Dr.M.Sugavaneswaran
 FUSED DEPOSISTION MODELING
POST PROCESSING

• The supports can be quickly removed without

damaging the model and without tools by
breaking using hand.
• This Breakaway Support System (BASS)
method is available for the polycarbonate
families PC, PC-ISO, and polyphenylsulfones
(PPSF).
• A support material called Water Works (WW)
can be removed automatically in a washing
station. This support material is for ABS, ABSi, Water can be jetted or
and PC-ABS and continues to spread, despite ultrasonically vibrated to accelerate
more and more safety requirements. the support removal process.
Source: http://articles.stratasys.com
9/24/2016 Dr.M.Sugavaneswaran
 FUSED DEPOSISTION MODELING
POST PROCESSING
• Thermoforming: Mount the PPSF part
on a base plate cut to a size that fits on
the thermoforming machine’s platen.
• The base plate can be made from any
rigid material that will withstand the
heat of the thermoforming process.
• Load the PPSF part in the vacuum
forming machine and insert a sheet of
PEEK material.
• To ensure that there is a strong
mechanical bond between the PPSF
part and PEEK film, adhesive-backed
materials are suggested.
Source: http://articles.stratasys.com
9/24/2016 Dr.M.Sugavaneswaran
 FUSED DEPOSISTION MODELING
POST PROCESSING

• Hysol E-20HP is a two-part epoxy that is dispensed

with a mixing gun and brushed onto the part in small
sections.
• Finishing Touch Smoothing Station seals a part’s
surfaces by exposing them to a vaporized smoothing
agent inside a chamber.
• Dipping FDM parts in solvent can substitute for using
the Smoothing Station when it is unavailable or the
part exceeds the chamber capacity.
• Few coats of paint and a little body putty can be an
inexpensive option
• Chemical treatment to decrease surface roughness

Source: http://articles.stratasys.com
9/24/2016 Dr.M.Sugavaneswaran
 FUSED DEPOSISTION MODELING
POST PROCESSING

• Electroplating deposits a thin layer of metal on the

surface of a part built using FDM process.
• This metal coating can be both decorative and
functional. The coating gives the appearance of
production metal or plated parts and provides a
hard, wear-resistant surface with reflective
properties.
• Parts which will be displayed for aesthetic or artistic
reasons or used as marketing tools
• Another aesthetic enhancement (which also
strengthens the part and improves wear resistance)
is chrome plating.

Source: http://articles.stratasys.com
9/24/2016 Dr.M.Sugavaneswaran
 FUSED DEPOSISTION MODELING
Advantages
ADVANTAGES
The advantages of FDM Rapid Prototyping are follows:

 Quick and cheap generation of models; The powder

that is used in SLS and the liquid for SLA are very costly
for example. In contrast, for the material that is used in
FDM technology, the filament, costs are much lower.
Different colours are possible;
;
 There is no worry of possible exposure to toxic chemicals
and lasers

 Wide range of machine to process material with high

melting temperature
 Other major ad- vantages include safe, laser-free operation and easy post
processing with the new water-soluble support material.
.
 FUSED DEPOSISTION MODELING
Disadvantages
DISADVANTAGES

 Restricted accuracy due to the shape of the material used: .

 Supports may be required
 Part strength is weak perpendicular to build axis.
 Temperature fluctuations during production could lead to delamination
 Although significant speed advancements have been made with newer FDM
systems, the mechanical process itself tends to be slower than laser-based
systems, therefore lack of build speed is a key disadvantage.
 Also, small features like a thin vertical column prove difficult to build with
FDM, due to the fact that each layer must have a physical start-and-stop
extrusion point. In other words, the physical contact with the extrusion tip can
sometimes topple, or at least shift, thin vertical columns and walls
 FUSED DEPOSISTION MODELING
Applications
APPLICATIONS

 The parts are either used as concept models, functional prototypes, or as

(direct manufactured) final parts

 Design model for assessing a product's final appearance and geometry;

 After assembling the parts, the working of complete products can be evaluated;

 High temperature plastic mould is used as soft

tool for Investment casting patterns and
injection moulding
 Ultrasonic Filament Modelling (UFM)

The process Ultrasonic Filament Modeling (UFM)

was first demonstrated by Hsu et al. in 2016
[Patten].

It is currently capable of additively fabricating

metal articles of greater than 95% density in
ambient conditions at room temperature.

The working principle of this process can be

thought of as the combination of Wire Bonding
and FDM: a solid metal filament is used as the
starting material to form a 3 dimensional object
via the metallurgical bonding between the
filaments and layers.
The ultrasonic vibration source is a piezoelectric crystal-based transducer oscillating in the kHz
frequency range.

During the UFM process, the tool delivers the acoustic energy to the interfaces between a
solid metal filaments and an existing metal substrate
11/14/2016 Dr.M.Sugavaneswaran
 Laser Engineered Net Shaping (LENS)

The key characteristics of this process are that

(1) the mechanical stress (and therefore

mechanical energy input) required to “shape”
the filament into the desired “track” geometry is
drastically reduced (<50%) in the presence of
applied acoustic energy as compared to the yield
strength of the material,

(2) the amount of mass transport across the

inter-filament and inter-layer interfaces to form
the metallurgical bonds is observed, and

These images depict filament track (3) the temperature rise of the UFM process is
shaping as well as metallurgical bonding nearly negligible (5 °C), a reflection of the high
with an adjacent tracks. coupling efficiency from acoustic energy input
into the required plasticity and mass transport.

11/14/2016 Dr.M.Sugavaneswaran
 Laser Engineered Net Shaping (LENS)

UFM is analogous to the FDM process where a

heated thermoplastic extruder directly “writes”
the tracks and layers that make up the 3D
component.

In UFM a solid metal filament is guided, shaped,

and then metallurgically bonded to the substrate
(or the previous layer) as well as the adjacent
filaments voxel by voxel using a guide tool on a
positioning system.

These unique characteristics enable the Ultrasonic Filament Model process introduced here to
be implemented within a desktop 3D printing environment.

Additionally, its unique nature of solid metal 3D printing at room temperature enables
simultaneous printing of polymers and metals, a materials combination not feasible in melt-
fuse-based metal additive manufacturing processes.
Sourec: https://www.thevirtualfoundry.com/
11/14/2016 Dr.M.Sugavaneswaran