2.

008x

Additive Manufacturing
MIT 2.008x

Prof. John Hart

 2.008x

E. Sachs, M. Cima, et al. MIT ~1990.

2.008x
 2.008x

Photo taken in Fall 2013 at MIT IDC

Earlier AM parts (arguably not the earliest)
2.008x
Photopolymerization
Kodama, Rev Sci Instr. 1981

Sintering of metal/ceramic powder

Housholder, 1979 (Patent)
Image: http://nsfam.mae.ufl.edu/Slides/Beaman.pdf
 2.008x

Additive Manufacturing (AM) refers to a process by

which digital 3D design data is used to build up a
component in layers by depositing material.

The term ‘3D printing’ is increasingly used as a

synonym for AM. However, the latter is more accurate in
that it describes a professional production technique
which is clearly distinguished from conventional
methods of material removal.

From the International Committee F42 for Additive Manufacturing Technologies, ASTM.
and http://www.eos.info/additive_manufacturing/for_technology_interested
Material removal (“top-down”)
2.008x

CNC machining image © 2016 Dungarvan Precision Engineering

Material addition
http://dpe.ie/cnc-milling/ “bottom-up”
Why is AM such a big
deal now? 2.008x

§ Wide availability of CAD/CAM

software.
§ Improved automation and
component technologies.
§ A growing library of ‘printable’
materials.
§ Major industry and government
investment.
§ Freedom to operate enabled by
patent expirations.
§ Momentum, confidence, and
creative vision.
Agenda: Additive
Manufacturing 2.008x

§ What and why?

§ Overview of AM processes
§ Extrusion AM (FFF/FDM)
§ Photopolymerization (SLA)
§ Powder bed fusion
(SLS/SLM)
§ Emerging AM technologies
§ Conclusion
 2.008x

Additive Manufacturing:

2. What can AM do and

why is it so important?
The AM industry today
2.008x

Services

Machines

Wohlers report 2016

2015: $5.2B AM machines and services

2015 growth = 26%
27-year CAGR = 26%

Worldwide mfg is ~$15 trillion (16% of

the world economy)
à AM = 0.03%.
The AM industry today
2.008x
“How do you use the parts made on your
industrial AM machines?”

Wohlers report 2016

Orthodontic aligners
(Align Tech)

Ti64 hip implant cups

(Arcam)
The diverse industrial uses of AM
GE leap fuel nozzle 2.008x

Airbus
Tooling: Linear Mold,
Aston Triform Shoe cleats: NIKE
Martin DB7:
Skyfall Modular products:
Google Ara

Custom airway stent: U. Michigan

Why Additive Mfg?
2.008x
§ Fast prototyping
§ Complex geometries
§ Mutiple materials; new materials
§ Enhanced performance
§ Low-volume (personalized?)
manufacturing
§ etc..
 Could this be machined?
2.008x

Gibson, Rosen, and Stucker. Additive Manufacturing Technologies

 2.008x

What additive
manufacturing
processes have you
used?

What was your

experience?
How good (or bad) is additive manufacturing?
(it depends on the process, machine, settings, and post-processing) 2.008x

Rate LOW 0.01-1 kg/hr

(getting better!)

Quality LOW ~0.1 mm resolution

(rate-quality tradeoff)

Cost HIGH $0.1-10 per gram!

(highly dependent on
material and process)

Flexibility AMAZING (if you know what to do)

Manufacturing:
value at scale 2.008x
AM lets us redefine
value and scale 2.008x

à How do we get
there?

Conner et al. Additive Manufacturing, 2014

AM lets us redefine
value and scale 2.008x

Conner et al. Additive Manufacturing, 2014

 2.008x

R. D’Aveni, Harvard Business Review, May 2015

 2.008x

Additive Manufacturing:

3. Overview of AM
processes
Fused filament Atlas V
rocket
fabrication (FFF/FDM) component
2.008x
(Stratasys)

Selective laser
sintering / melting (SLS/SLM)

Stereolithography
(SLA) EOS

http://www.c3plasticdes
ign.co.uk/stereolithogra
phy-process.html

Formlabs /
www.deschaud.fr

Materialise
Material and Binder Jetting Voxeljet
Stratasys/Objet
2.008x

Objet

Laminated Object Directed Energy Deposition

Manufacturing (LOM)

https://en.wikipedia.org/wiki/Laminat
ed_object_manufacturing

Optomec

Sciaky
Fabrisonic mCor
 The 7 AM methods (from ASTM F42)
2.008x
Low energy

§ Vat photopolymerization (à SLA): material is

cured by light-activated polymerization.
§ Material jetting (à Objet): droplets of build material
are jetted to form an object.
§ Binder jetting (à 3DP): liquid bonding agent is jetted
to join powder materials.
§ Material extrusion (à FFF/FDM): material is
selectively dispensed through a nozzle and solidifies.
§ Sheet lamination (à LOM): sheets are bonded to
form an object.
§ Powder bed fusion (à SLS/SLM): energy (typically
a laser or electron beam) is used to selectively fuse
regions of a powder bed.
High energy

§ Directed energy deposition (à LENS): focused

thermal energy is used to fuse materials by melting
as deposition occurs.
We must master all the steps
2.008x

Gibson, Rosen and Stucker, Additive Manufacturing Technologies

2.008x
 2.008x

Additive Manufacturing:

4. Extrusion processes

(i.e., Fused Filament Fabrication, FFF

Fused Deposition Modeling, FDM)
 2.008x

Nozzle

Build platform
 2.008x

Image © Ultimaker B. V.

Image © Stratasys Ltd.

Ultimaker 2
~US$2,500: 10 x 9 x 8”

Stratasys Fortus
~US$150,000: 16 x 14 x 16”
~US$400,000: 36 x 24 x 36”

iPhone dock
Matt Haughey (CC BY-NC-SA 2.0)

Aircraft duct
Image © WTWH Media LLC
 Fused Deposition Modeling (FDM)
2.008x

from Solid Concepts: excerpt of https://youtu.be/WHO6G67GJbM

Stratasys FDM
materials 2.008x
2.008x
FDM part nomenclature
2.008x

Part

Support
Raft (base)

Build plate
Discretization and toolpath effects
2.008x

Accuracy Strength

Diagrams from Gibson, Rosen and Stucker, Additive Manufacturing Technologies

Polymer extrusion in FDM
2.008x
Thermoplastic
à amorphous polymer network,
linear chain architecture

The chains align then slip during flow

Heated bed Extruder
ABS ~80C ABS ~260C

Tf = forming temp.

Malloy, Plastic Part Design Injection Molding

Comparison to injection into a mold

Osswald et al., International Plastics Handbook

Groover, Fundamentals of Modern Manufacturing

A dual extruder
2.008x
Extrusion force vs temperature
Extruder
2.008x
à Force increases with feed rate Load+cell

à Force is greater at lower temperature Heater

assembly

à Force saturates at ~60 N

70.0

60.0
59+N
50.0
Extruder(Force((N)

40.0
200+C
30.0 230+C
260+C
20.0

10.0

0.0
0 2 4 6 8 10 12 14 16
Feed(Rate((mm/s)
Jamison Go
Shear failure of the filament Drive&wheel

2.008x

Filament&
shear&area
Material&
under&drive&
wheel&teeth

1 mm
Feed Direction

Material shear
(extrusion failure)

Drive knurls
(normal operation)
Geometry of the FDM nozzle
2.008x

𝑑𝑑# 𝑙𝑙# 𝑰𝑰

𝛽𝛽
𝑙𝑙$ 𝑰𝑰𝑰𝑰
I
Heater block
II, III Extrusion nozzle
𝑑𝑑$ 𝑰𝑰𝑰𝑰𝑰𝑰

Zone I: heating
Zone II: transition
Zone III: area reduction (dominates pressure drop)
Extrusion rate is limited by heat transfer
à Feed rates found to cause extrusion failure correspond with inadequate 2.008x
filament core temperatures

1 mm/s 3 mm/s 9 mm/s

1 mm/s

3 mm/s
Temperature (C)

9 mm/s
Big area additive manufacturing (BAAM!)
2.008x

ABS blended with chopped carbon fiber

~5 mm bead size
2.008x
2.008x
2.008x
2.008x
Stratasys Mojo = 65 min
2.008x

BAAM ~30 min

FDM: other topics
§ Support criteria and 2.008x

removal

FDM figurine Image © 3D Genius

§ Mechanics (= anisotropy)

Ahn et al., “Anisotropic Material

Properties of Fused Deposition
Modeling (FDM) ABS,” 2002.
§ Surface finishing

Smoothing FDM Images © Shapeways, Inc.

 2.008x

Additive Manufacturing:

5. Photopolymerization

(Stereolithography, SLA)
Stereolithography (SLA)
2.008x
à Material is cured by light-activated polymerization.

Materialise NV (Belgium): excerpt from https://www.youtube.com/watch?v=98xG86GKj7A

 2.008x

Image © CustomPartNet
Applications of SLA
2.008x

FOPAT Production Inc.

Phidgets
Short-run tooling
Prototype parts

Tri-Tech 3D © Moises Fernandez Acosta

Innovated Solutions

Invisalign

Personalized
products
Presentation models
2.008x
2.008x
SLA vs FDM: layer thickness
2.008x

Form1 (SLA) Stratasys Mojo (FDM)

SLA vs FDM: toolpath
2.008x

Form1 (SLA) Stratasys Mojo (FDM)

How the flash of light works:
photopolymerization (a.k.a photocuring) 2.008x

à Crosslinked network
(thermoset)

Image © Formlabs

Yagci Polymer Research Group, Istanbul Technical University

hv
PI RŸ
initiation
k1
M+RŸ P1Ÿ
kp
PnŸ+M Pn+1Ÿ propagation
ktc
PnŸ+PmŸ Mn+m /Mn+Mm termination by combination
A photoinitiator (PI) turns into a primary radical (RŸ) through photon excitation. A chain
grows by the addition of monomer units (M) to a polymeric radical of length n (Pn), finally
forming stable polymer units of length n (Mn).
1. The laser beam scans the surface of the resin
Point i (xi yi)
y (xstart, ystart)
(xend, yend) 2.008x
yi
x
v

Amplitude of electric
2. Each laser pass cures a parabolic
Intensity [W/m2]
field [V/m] cross-section of the resin

position x

3. Resin properties determine the relationship

between light exposure and cure depth
= 25.4 microns)
(1 mil = 0.001”

Figure 1 (b) from "Epoxy and Acrylate Stereolithography

Resins: In-Situ Measurements of Cure Shrinkage and
Stress Relaxation" by Guess, et al.
From an example SLA resin

Gibson, Rosen and Stucker, Additive Manufacturing Technologies

 The complete scan pattern
2.008x
A ‘Star-weave’ pattern is Side view
used to raster the surface Layers
Top view
Hatch
Border

0.01 inch

Side view hs

à This allows the resin to shrink

locally while curing (it happens)
while minimizing overall part
shrinkage and residual stress.

Gibson, Rosen and Stucker, Additive Manufacturing Technologies

 2.008x

?
Inside the Form1
2.008x

Formlabs

Laser

Andrew (bunnie) Huang (CC BY-SA 3.0)

 2.008x

3D Systems, Inc. May 2016

SLA: other topics
2.008x
§ Support criteria and
removal

§ Mechanics and durability

§ Surface finishing
 2.008x

Additive Manufacturing:

6. Powder bed fusion

(i.e., Selective Laser Sintering, SLS
Selective Laser Melting, SLM)
Selective Laser Melting (SLM)
2.008x

Excerpt from: https://www.youtube.com/watch?v=zqWOrwBzOjU

 2.008x

EOS GmbH Electro Optical Systems

Applications of SLM parts
Aerospace 2.008x
AMG Advanced Metallurgical Group
Medical

Airbus (Image © BBC)

Manufacturing

General Electric
Company

Arcam AB

SpaceX
EOS (Images © MachineDesign.com)
Powder fusion AM applies to many materials
2.008x
Dyson

Image © Best Vacuum Cleaners Image from VintageHoover via YouTube

Reviews

From J.P. Kruth

 2.008x

at Nanyang Technological University (Singapore), August 2014

 2.008x

Critical process parameters

§ Laser power
§ Laser scan speed
§ Laser scan pattern
§ Particle size and packing density
§ Layer uniformity and thickness
§ Bed temperature
§ And more..
Figure 1 from “Binding Mechanisms in Selective Laser Sintering and
Selective Laser Melting” by Kruth, et al. 2004
Lasers: wavelength and absorption
2.008x

Figure from "Additive Manufacturing Technologies" by Gibson, et al. (2010)

What’s different for SLM? (vs. FDM, SLA)
2.008x
§ Powder = can be ~anything (flexibility, bulk properties!)
à Typically ~10-100um diameter (wide size distribution)

§ Complexity of powder handling (why?)

§ Flammable
§ Inhalation risk
§ Oxidation/contamination à often need inert atmosphere for metals

§ Energy required = high

§ SLA: 0.1 W for photopolymerization (at ~1 m/s scan)
§ FDM: 1-10 W for melting the filament
§ SLM: 100-1000 W for melting the powder (at ~1-10 m/s scan)

§ Post-processing: powder removal, machining away metal

support
SLM: Mechanism Cross-section of SLM part

2.008x
Before and after
2.008x

Advanced Powders and Coatings Inc. Figure 5 f) from "Analysis of defect generation in Ti-6Al-4V parts made using
powder bed fusion additive manufacturing processes" by Gong, et al., Additive
Manufacturing (2014)

0-25 um 15-45 um 45-106 um

Advanced Powders and Coatings Inc.

Process map: SLM of Ti64
2.008x
Zone%I%(fully%
Zone I: Fully dense (few defects) dense)
Zone II: Sub-surface porosity due to excess
heating (gas bubble generation, trapped, do not
appear on surface)
Zone III: Insufficient melting
OH: Serious surface deformation (jams recoater)

Zone%II
(subsurface%voids)

Increasing energy
density

Gong, et al, “Analysis of defect generation in Ti–6Al–4V parts

made using powder bed fusion additive manufacturing
processes,” Additive Manufacturing, 2014.
Process map: SLM of Ti64
2.008x
Zone)III
Zone I: Fully dense (few defects) (underheat)
Zone II: Sub-surface porosity due to excess
heating (gas bubble generation, trapped, do not
appear on surface)
Zone III: Insufficient melting
OH: Serious surface deformation (jams recoater)

Overheated)

Gong, et al, “Analysis of defect generation in Ti–6Al–4V parts

made using powder bed fusion additive manufacturing
processes,” Additive Manufacturing, 2014.
Prof. JP Kruth says…
2.008x

During SLM, the short interaction of powder bed and

heat source caused by the high scanning speed of
the laser beam leads to rapid heating, melting
followed by drastic shrinkage (from 50% powder
apparent density to ~100% density in one step), and
circulation of the molten metal driven by surface
tension gradients coupled with temperature
gradients.

The resulting heat transfer and fluid flow affect the size
and shape of the melt pool, the cooling rate, and the
transformation reactions in the melt pool and heat-
affected zone.

The melt pool geometry, in turn, influences the grain

growth and the resulting microstructure of the part.
Chaos in the melt pool!
2.008x
à Evaporation and recoil
à Ejection of ‘sparks’ (hot droplets)

Presented by Dr. Wayne King (LLNL) at ASME AM3D 2015

Typical (general) scan patterns
2.008x

Carter et al. J. Alloys and Compounds 2014.

Gibson et al. 2015

 Success! Lots of parts in
close proximity. 2.008x

Renishaw plc

Ti frame = 1400g
Renishaw Plc; http://www.core77.com/blog/digital_fabrication/from_the_uk_the_worlds_first_3d-
printed_bike_frame_26463.asp
2.008x
 Mechanical properties of SLM Ti64
à Fine microstructure = high strength 2.008x

à Small defects = lower ductility than standard (wrought) material

à Highly dependent on process parameters including post-print annealing!

Vrancken, et al. (2012) doi:10.1016/j.jallcom.2012.07.022

SLM market dynamics
EOS M 400
2.008x

From manufacturer data, 2015.

 Ti6Al4V hip implant cups
§ >40,000 acetabular (hip cup) implants in patients (Wohlers 2014); 2.008x
approved in Europe and US.
§ Surface texture promotes osseointegration (bone attachment).
§ Arcam (EBM):
§ “now allows the ability to specify pore geometry, pore size, and density and
roughness of structures for trabecular structures and surfaces.”
§ 16 cups built simultaneously in 8 hours à then post-processing (intensive).

EOS/Arcam/Within; orthoinfo.aaos.org/topic.cfm?topic=a00377
 2.008x

Additive Manufacturing:

7. Emerging Process
Technologies
 High speed SLA: Carbon3D ‘Continuous liquid
interphase production’ (CLIP) 2.008x

Ford / carbon3D

Dead zone thickness ~20-30 μm

Carbon3D, Inc. / Tumbleston et al. Science, 2015.

TED talk by Prof. Joe DeSimone: Legacy effects / carbon3D
https://www.ted.com/talks/joe_desimone_what_if_3d_printing_was_25x_faster?language=en
Industrial automation of AM
2.008x
Additive Industries: http://additiveindustries.com/Industrial-am-systems/Metalfab1
screenshot from https://www.youtube.com/watch?v=TssX2JsL0uk
Mori AM and machining
Hybrid
2.008x
2.008x
2.008x
AM of advanced materials
Fiber composites (Markforged) Integrated electronics 2.008x
(Voxel8)
© MarkForged, Inc.

© MarkForged, Inc.

© MarkForged, Inc.

Images © www.3Ders.org, Voxel8

 2.008x

Additive Manufacturing:

8. Conclusion
 2.008x

Cost Rate

Quality Flexibility
Challenges to
accelerate AM 2.008x

§ Design tools and data

management to fully realize the
potential of AM.
§ Process control; higher quality
at faster rate and process/part
qualification.
§ Standards.

§ Education!
(IBM report)
AM will catalyze digital supply chains
2.008x

http://www-
935.ibm.com/services/us/gbs/thoughtlead
ership/software-defined-supply-chain/
References
2.008x
1 Introduction

Image of GE fuel nozzle airflow diagram © 2016 General Electric

GE leap fuel nozzle image Copyright © 2016 Penton

Titanium aircraft brackets produced by conventional manufacturing and additive

manufacturing © 2016 Business Wire

Aston Martin DB5 prop from the movie "Skyfall" Photo © Voxeljet AG

X-ray of a child's airway and a 3D printed bioresorbable airway stent, Image Copyright ©
2016 Massachusetts Medical Society. All Rights Reserved.

Tooling inserts with internal cooling channels ©Linear AMS All Rights Reserved

Tooling mold for sheet metal forming, photo © Dave Pierson.

Image in Fast Company & Inc © 2016 Mansueto Ventures, LLC

Project Ara modular smartphone components, photo © Google, Inc.

Google Ara modular smartphone photo © 2016 AOL Inc. All Rights Reserved.
References
2.008x
3D printed MIT dome © John Hart

Hagia Sofia, Istanbul, photo on boisestate.edu by E.L. Skip Knox

Cima, Micheal, et al. "Three-dimensional printing techniques: US 5387380 [P]."

Photo of first 3D printer at MIT © John Hart

Clear printed part: Figure 7 from "Automatic method for fabricating a three-dimensional
plastic model with photo-hardening polymer" by Kodama, Rev. Sci. Instrum. 52 (11),
November 1981, 1770-1773; © 1981 American Institute of Physics

Patent schematic: Figure 1 from "Automatic method for fabricating a three-dimensional

plastic model with photo-hardening polymer" by Kodama, Rev. Sci. Instrum. 52 (11),
November 1981, 1770-1773; © 1981 American Institute of Physics

Molding Process US Patent 4247508 schematic, figure 15. This work is in the public
domain.

Photos from slide presentation by Joseph Beaman, University of Texas at Austin.

CNC machining photo © Dungarvan Precision Engineering

FDM printing with a Solidoodle 3D printer © John Hart

Article Copyright by ASTM Int'l (All Rights Reserved).

References
2.008x
2 Importance of Additive Manufacturing

Additive manufacturing analytics, Image © Wohlers Associates, Inc.

Image of GE fuel nozzle airflow diagram © 2016 General Electric

GE leap fuel nozzle image Copyright © 2016 Penton

Titanium aircraft brackets produced by conventional manufacturing and additive

manufacturing © 2016 Business Wire

Aston Martin DB5 prop from the movie "Skyfall" Photo © Voxeljet AG

X-ray of a child's airway and a 3D printed bioresorbable airway stent, Image Copyright ©
2016 Massachusetts Medical Society. All Rights Reserved.

Image of tooling with cooling channels ©Linear AMS All Rights Reserved

Photo of tooling mold for sheet metal forming © Dave Pierson.

Image in Fast Company & Inc © 2016 Mansueto Ventures, LLC

Project Ara modular smartphone components, photo © Google, Inc.

Google Ara modular smartphone photo © 2016 AOL Inc. All Rights Reserved.
References
2.008x
Image of pie chart © Wohlers Associates, Inc.

Invisalign clear dental braces, image © invisalign.com 2016

Titanium hip implant, image © Arcam AB.

3D printing potato chips, video ©1996-2016 TheStreet, Inc. All Rights Reserved.

Figure 1.3 from "Additive Manufacturing Technologies (2nd Edition)" by Gibson, et al.
(2015) © Springer International Publishing AG, Part of Springer Science+Business Media

iPhone 5, photo by Justin Sullivan © Getty Images.

Volvo C30 T5 R-design hatchback, photo © Auto-Power-Girl.com 2006-2015. All Rights

Reserved.

Water desalination facility, photo © F.D.W.A. All Rights Reserved.

Froti-Lay potato chip production, photo by Peter Desilva of the New York Times. © 2016
The New York Times Company.

Lays potato chips, image © 2016 Frito-Lay North America, Inc.

DePuy hip implant, image © DePuy Synthes 2014-2016. All Rights Reserved.

Bathroom sink, photo by User: Tomwsulcer via wikimedia - CC0. This work is in the public
domain.
References
2.008x
"Making sense of 3-D printing: Creating a map of additive manufacturing products and
services" Figures 2 and 6, by Conner, et al., Additive Manufacturing (2014). © Elsevier
B.V.

Photo of Harvard Business Review Cover by Bruce Peterson. Copyright © 2016 Harvard
Business School Publishing. All Rights Reserved.

3 Overview

Rocket air duct printed by FDM image copyright © 2016 Stratasys Direct, Inc. All Rights
Reserved.

Video if Solidoodle FDM printer, © John Hart

Stereolithography process, image © www.C3plasticdesign.co.uk

Large scale stereolithography, Video by Materialise NV © 2016

SLS diagram Figure 1 from Title: Binding Mechanisms in Selective Laser Sintering and
Selective Laser Melting; Authors: P. Kruth, P. Mercelis, L. Froyen, Marleen Rombouts;
Journal: SSF 2004 Proceedings; Year: August 4, 2004; Pages: 44-59. © Emerald Group
Publishing Limited

Photo of EOS selective laser sintered parts © John Hart

References
2.008x
Inkjet droplet impact on a glass sheet, image Copyright © Shimadzu Corporation. All
Rights Reserved.

Objet digital material composition, image Copyright © 2016 Stratasys Direct, Inc. All
Rights Reserved.

Fabrisonic lamintated object manufacturing sample, photo © Fabrisonic 2016

Laminated object manufacturing printing head, photo Copyright © 2016

ENGINEERING.com, Inc.

Photo oF Optomec LENS metal laser deposition copyright 2016 Optomec. All Rights
Reserved

Directed energy deposition schematic, image © Oerlikon Corporation AG, Metco

Electron beam additive manufacturing of a metal bowl, photo © 2016 Sciaky Inc. All
Rights Reserved.

Schematic of the vat photopolymerization process, image © 2016 Loughborough

University. All Rights Reserved.

Schematic of the fused deposition modeling process, image © 2016 Loughborough

University. All Rights Reserved.

Material jetting combined with photopolymerization, image Copyright © 2009

CustomPartNet. All Rights Reserved.
References
2.008x
Sheet lamination schematic. image © 2016 Loughborough University. All rights reserved.

Selective laser sintering schematic, image © 2016 Loughborough University. All Rights
Reserved.

Directed energy deposition schematic, image © 2016 Loughborough University. All Rights
Reserved.

CAD to part process, Figure 1.2 from "Additive Manufacturing Technologies (2nd Edition)"
by Gibson, et al. (2015). © Springer International Publishing AG, Part of Springer
Science+Business Media

FDM process diagram © John Hart

3D printed Poseidon sculpture, photo © Gilles-Alexandre Deschaud.

Selective laser melting in action, video © John Hart

Binder jetting process schematic, image Copyright © 2016 Penton

Sand mold core made by binder jetting and cast part, photo © Voxeljet AG

Soft polymer heart printed by binder jetting © John Hart

Ultrasonic additive manufacturing, image © Copyright 2016, Peerless Media, LLC. All
Rights Reserved
References
2.008x
Laminated object manufacturing process schematic, image by User: Laurens van
Lieshout (LaurensvanLieshout) via Wikimedia. (CC BY-SA) 3.0

4 Extrusion Processes

FDM printing using the Solidoodle printer, video © John Hart

FDM process diagram © John Hart

Ultimaker FDM printer, image © 2016 Ultimaker B.V.

3D printed iPhone 5 dock, image by Matt Haughey (CC BY-NC-SA 2.0)

Stratasys Fortus 400mc printer, image Copyright © 2016 Stratasys Direct, Inc. All Rights
Reserved.

Aircraft air duct, image Copyright © 2016 · All Rights Reserved WTWH Media LLC

Fused deposition modeling, video Copyright © 2016 Stratasys Direct, Inc. All Rights
Reserved.

Stratasys FDM materials list, image Copyright © 2016 Stratasys Direct, Inc. All Rights
Reserved.

UP Mini time lapse video © John Hart

3D printed ship wheel, image © John Hart

References
2.008x
CAD rendering of a Yo-Yo assembly © MIT

FDM filament path, Figures 6.3 and 6.5 from "Additive Manufacturing Technologies (2nd
Edition)" by Gibson, et al. (2015). © Springer International Publishing AG, Part of
Springer Science+Business Media

Amorphous polymer network, Figure 1.2 from "Plastic Part Design Injection Molding (2nd
edition)" by Malloy (1994). © Hanser Publishers (1994)

Photo of FDM printed part on a Solidoodle printer © John Hart

Injection molding machine diagram, Figure 13.21 from Title: Fundamentals of Modern
Manufacturing; Author: Mikell P. Groover; © Wiley; (2010);

Tensile stress and strain as a function of temperature for an amorphous thermoplastic,

Figure 2.26 from "International Plastics Handbook" by Osswald et al. © Hanser
Publishers (2006).

Photograph of dual nozzle extruder © John Hart

Extrusion force versus feed rate, Image by Jamison Go © MIT. All Rights Reserved.

Pinch wheel teeth and shear area CAD schematic, image by Jamison Go © MIT. All
Rights Reserved.

Picture of sheared filament, image by Jamison Go © MIT. All Rights Reserved.

References
2.008x
Diagram of filament material flow, mage by Jamison Go © MIT. All Rights Reserved.

Big Area Additive Manufacturing system printing a chair, video © John Hart

Big Area Additive Manufacturing feedstock, image © John Hart

Layering in 3D printed chair with measuring tape reference, image © John Hart

Big Area Additive Manufacturing Facility, Oak Ridge National Laboratory, image © John
Hart

Willys Jeep 3D printed model, image © John Hart

Scale model of 3D printed chair, printed on the Mojo FDM printer, © John Hart

Chair printed by Big Area Additive Manufacturing, © John Hart

FDM overhang angle illustration, image © John Hart

Image © 2015 3D Genius – The Home of 3D Printing.

Fracture surface SEM image of FDM ABS specimen, figure 11 from Title: Anisotropic
Material Properties of Fused Deposition Modeling (FDM) ABS; Authors: S. H. Ahn, M.
Montero, D. Odell, S. Roundy, and P. K. Wright; Journal: Rapid Prototyping Journal;
Volume: 8; Number: 4; Year: 2002; Pages: 248-257. © Emerald Group Publishing Limited
References
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SEM images showing the effect of Stratasys vapor smoothing on FDM part surfaces,
photo © 2016 Shapeways, Inc.

5 Photopolymerization

Materialise large scale SLA, video by Materialise NV © 2016

Prototype SLA enclosure, image © 2016 Phidgets

Short-run SLA tooling, image © 2016 FOPAT

Engine block printed by binder jetting, Image © Tri-Tech3D

SLA city scape, image © Copyright - Innovated Solutions

Invisalign clear braces, image © invisalign.com 2016

Stereolithography process diagram, image Copyright © 2009 CustomPartNet. All Rights

Reserved.

Materialise large scale SLA, still from video by Materialise NV © 2016

3D printed prototype hamster and hamster wheel, image © John Hart

SLA and FDM printed salt shakers, photo © John Hart

References
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Photopolymerization, diagram by Dr. Yusuf Yagci of Istanbul Technical University.
Copyright 2010 All Rights Reserved.

Thermoset polymer structure, Figure 7.5d from Title: Manufacturing Engineering &
Technology (6th Edition); Authors: Serope Kalpakjian, Steven Schmid; © Prentice Hall;
(2009)

Light exposure intensity distribution, © MIT. All Rights Reserved.

Cure depth in photopolymerization, Figures 4.6 and 4.7 from "Additive Manufacturing
Technologies (2nd Edition)" by Gibson, et al. (2015). © Springer International Publishing
AG, Part of Springer Science+Business Media

Laser scanning patterns, Figures 4.10 b) and 4.12 from "Additive Manufacturing
Technologies (2nd Edition)" by Gibson, et al. (2015). © Springer International Publishing
AG, Part of Springer Science+Business Media

Time lapse of 3D printing using a Form 1, video © John Hart

Formlabs photoresin, photo © Formlabs 2016, Inc. All Rights Reserved.

Exposure at a point in SLA, © MIT. All Rights Reserved.

Cured resin cross-section, figure 1 (b) from Title: Epoxy and Acrylate Stereolithography
Resins: In-Situ Property Measurements; Authors: T. R. Guess, R. S. Chambers, T. D.
Hinnerichs; Year: January 1996; Journal: Sandia Report SAND95-2871. This work is in
the public domain.
References
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SEM image and turbine blade photo, image © John Hart

Formlabs Form 1 printer specifications, article © Formlabs 2016, Inc. All Rights
Reserved.

Formlabs Form 1 teardown, photo by (bunnie) Andrew Huang is licensed under a

Creative Commons Attribution-ShareAlike 4.0 International License.

3D Systems ProX 950 specifications, article © 2014 by 3D Systems Inc. All Rights
Reserved.

6 Powder Bed Fusion

EOS tooling, video © EOS GmbH Electro Optical Systems

EOS rook made by selective laser sintering, image © EOS GmbH Electro Optical
Systems

Jet engine cross-section, image ©AMG Advanced Metallurgical Group, 2010 All Rights
Reserved.

GE LEAP fuel nozzle, image © 2016 General Electric

Low pressure turbine blade, photo © Arcam A.B.

SpaceX inconel rocket chamber, photo © Elon Musk via Twitter.

References
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Airbus bracket manufactured by conventional manufacturing and 3D printing, photo
Copyright © 2016 BBC.

EOS tooling with integrated cooling channels, image Copyright © 2016 Penton

Hip implant, image Copyright ©1995-2016 by the American Academy of Orthopaedic

Surgeons.

Arcam 3D printed implant, image © Arcam AB.

Arcam skull remodeling implant, image © Arcam AB.

Polyamide, steel, titanium, composite and ceramic parts, image © Prof. Dr. Ir. Jean-Pierre
Kruth; KU Leuven university, Belgium

Dyson DC25, image Copyright © 2011-2014 Best Vacuum Cleaners Reviews

Dyson rapid prototype SLS, image from www.vintagehooveremporium.com © 2005 All

Rights Reserved.

SLM solutions 250HL printer, image © John Hart

SLS diagram figure 1 from Title: Binding Mechanisms in Selective Laser Sintering and
Selective Laser Melting; Authors: P. Kruth, P. Mercelis, L. Froyen, Marleen Rombouts;
Journal: SSF 2004 Proceedings; Year: August 4, 2004; Pages: 44-59. © Emerald Group
Publishing Limited
References
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Absorptivity of various metals, Figure 5.10 from "Additive Manufacturing Technologies" by
Gibson, et al. (2010). © Springer International Publishing AG, Part of Springer
Science+Business Media

Side view of an SLM micrograph figure 15 c) from Title: Part and material properties in
selective laser melting of metals; Authors: J.-P. Kruth, M. Badrossamay, E.Yasa, J.
Deckers, L. Thijs, J. Van Humbeeck; Journal: Proceedings of the 16th International
Symposium on Electromachining; Year: 19-23 April, 2010. © Shanghai Jiaotong
University Press, Shang Hai, 2010

Epitaxial growth during selective laser sintering, Figure 2 from "Physical Aspects of
Process Control in Selective Laser Sintering of Metals" by Das, Advanced Engineering
Materials 5(10), 2003. © Shanghai Jiaotong University Press, Shang Hai

SLM processed Ti-6Al-4V powder, Figure 5 f) from "Analysis of defect generation in Ti-
6Al-4V parts made using powder bed fusion additive manufacturing processes" by Gong,
et al., Additive Manufacturing (2014). Copyright © 2016 Elsevier B.V.

SEM images of SLM processed Ti-6Al-4V powder, Figure 5 a) and f) from "Analysis of
defect generation in Ti-6Al-4V parts made using powder bed fusion additive
manufacturing processes" by Gong, et al., Additive Manufacturing (2014). Copyright ©
2016 Elsevier B.V.

SLM process window, Figure 4 from "Analysis of defect generation in Ti-6Al-4V parts
made using powder bed fusion additive manufacturing processes" by Gong, et al.,
Additive Manufacturing (2014). Copyright © 2016 Elsevier B.V.
References
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SEM images of Ti-6Al-4V powder, Figure 5 d) and k) from "Analysis of defect generation
in Ti-6Al-4V parts made using powder bed fusion additive manufacturing processes" by
Gong, et al., Additive Manufacturing (2014). Copyright © 2016 Elsevier B.V.

Schematic of the laser melt pool, Figure 16 from "Analysis of defect generation in Ti-6Al-
4V parts made using powder bed fusion additive manufacturing processes" by Gong, et
al., Additive Manufacturing (2014). Copyright © 2016 Elsevier B.V.

Title crop of paper: Part and material properties in selective laser melting of metals;
Authors: J.-P. Kruth, M. Badrossamay, E.Yasa, J. Deckers, L. Thijs, J. Van Humbeeck;
Journal: Proceedings of the 16th International Symposium on Electromachining; Year: 19-
23 April, 2010. © Shanghai Jiaotong University Press, Shang Hai

Prof. J.P. Kruth, Photo Copyright © KU Leuven

Video by A.J. Hart, of Wayne King at Lawrence Livermore National Laboratory, U.S. Dept.
of Energy. This work is in the public domain.

Island scan strategy in SLM, Figure 3 from "The influence of the laser scan strategy on
grain structure and cracking behaviour in SLM powder-bed fabricated nickel superalloy"
by Carter, et al., Journal of Alloys and Compounds (2014). Copyright © 2016 Elsevier
B.V.

Scanning path for powder bed fusion, Figure 5.7 from "Additive Manufacturing
Technologies (2nd Edition)" by Gibson, et al. (2015). © Springer International Publishing
AG, Part of Springer Science+Business Media
References
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Empire 3D printed bicycle frame, Photo © 2001-2016 Renishaw plc. All Rights Reserved.

Picture of Tim Simpson, Photo © Tim Simpson.

Mechanical test of SLM printed specimens before and after heat treating, Figure 8 from
"Heat treatment of Ti6Al4V produced by Selective Laser Melting: Microstructure and
Mechanical properties" by Vrancken, et al., Journal of Alloys and Compounds (2012).
Copyright © 2016 Elsevier B.V. or its licensors or contributors

EOS M400 printer, photo © EOS GmbH Electro Optical Systems

Machine cost versus build volume, image © John Hart

Titanium hip implant, image © Arcam AB.

7 Emerging Technologies

Continuous liquid interface printing of an Eifel Tower model, video © Carbon

Continuous Liquid Interface Production, Figure 1 (A) and (C 3) from "Continuous liquid
interface production of 3D objects" by Tumbleston, et al., Science Magazine 347(6228),
March 20, 2015. © 2016 EBSCO Industries, Inc. All Rights Reserved.

Rapid prototype of oil fill tube, Photo © Carbon

3D printed "Iron Man" articles Image Copyright © 2016. 3DR Holdings, LLC, All Rights
Reserved.
References
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Rendering of Additive Industries MetalFAB1 copyright © Additive Industries

Still of Additive Industries MetalFAB1 copyright © Additive Industries

DMG Mori Lasertec 65 additive and subtractive manufacturing machine, Video Copyright
© 2016 DMG MORI All Rights Reserved.

DMG Mori Research Facility, image © John Hart

Turbine blades manufactured by DMG MORI © John Hart

Mark One composite 3D printer, photo Copyright ©2016 - 3D Printing Blog -

FDM printed bike crank with continuous carbon fiber reinforcement, image ©2016
Markforged, Inc.

Kevlar reinforced 3D printed pipe bender, Image ©2016 Markforged, Inc.

Volex 8 quadrotor photo and X-ray image Copyright © 2011-2016. www.3Ders.org All
Rights Reserved.

8 Conclusion

Part printed on a Solidoodle FDM printer © John Hart

Supply chain of the future article © IBM