Lecture 01 - Introduction To Additive Manufacturing - Notes

MME 9651
Additive Manufacturing
Lecture 01
Introduction to Additive Manufacturing
September 14, 2021
Dr. Mostafa Yakout

About the course
• Instructor
Mostafa Yakout, Ph.D. in Mechanical Engineering
• Course description
Additive manufacturing offers a new paradigm for product design, manufacturing,
metallurgy, and functionality. This course provides graduate students with an in-
depth understanding of additive manufacturing processes and applications. The
course covers the fundamental aspects and recent developments in additive
manufacturing including design for additive manufacturing, design and
metallurgical benefits of additive manufacturing, additive manufacturing
processes for polymers and metals, quality aspects in additive manufacturing,
and future trend of additive manufacturing in industry.
• Lectures
Tuesdays 3:30 - 6:30 PM Eastern Time (Room SEB 2202)
Copyright © M. Yakout 1
Course outline
Week Date Topic Due
1 Tue Sep 14, 2021 Introduction to Additive Manufacturing

Additive Manufacturing Processes
2 Tue Sep 21, 2021
History of Additive Manufacturing
3 Tue Sep 28, 2021 Design Rules in Additive Manufacturing
Benefits of Additive Manufacturing
4 Tue Oct 05, 2021 Assignment 1
Functionally Graded Materials
5 Tue Oct 12, 2021 Applications of Additive Manufacturing
6 Tue Oct 19, 2021 Concept of Vat Polymerization Project Presentation

Polymer Material Jetting
7 Tue Oct 26, 2021 Group Quiz
Material Extrusion
8 Tue Nov 02, 2021 Powder Bed Fusion
Solidification of Metals
9 Tue Nov 09, 2021 Assignment 2
Production of Metal Feedstock
Directed-Energy Deposition of Metals
10 Tue Nov 16, 2021
Binder Jetting Process
Post-processing of Additive Manufacturing Parts
11 Tue Nov 23, 2021 Final Report
Monitoring in Additive Manufacturing
12 Tue Nov 30, 2021 Final Exam
Course evaluation
Assessment Due Date Weight
Assignment 1 Tue Oct 05, 2021 15%
Assignment 2 Tue Nov 09, 2021 15%
Group Quiz Tue Oct 26, 2021 10%
Project Progress Presentation Tue Oct 19, 2021 10%
Project Final Report Tue Nov 23, 2021 20%
Final Exam Tue Nov 30, 2021 30%
Total 100%
• Resources (optional)
– Bourell D.L., Frazier, W., Kuhn, H., Seifi, M. (editors). ASM Handbook, Volume 24:
Additive Manufacturing Processes. ASM International 2020.
– Gibson, I., Rosen, D., Stucker, B. Additive Manufacturing Technologies: 3D Printing,
Rapid Prototyping, and Direct Digital Manufacturing. 2nd Edition. Springer 2015.
– Yadroitsev, I., Yadroitsava, I., Du Plessis, A., MacDonald, E. (editors). Fundamentals of
Laser Powder Bed Fusion of Metals. 1st Edition. Elsevier 2021.
– Standards under the Jurisdiction of the ASTM Committee F42 on Additive
Manufacturing Technologies, as well as selection of published articles.
ASTM F42 Committee
Space
Aerospace
Biomedical
device
Automotive and
transportation
Electronics
Dental Tooling
Additive manufacturing – ISO/ASTM 52900:2015
• Additive Manufacturing (AM)

– Process of joining materials to make parts from 3D model data, usually layer
upon layer, as opposed to subtractive manufacturing and formative
manufacturing methodologies.
• Other terminologies
– Additive fabrication, additive processes, additive techniques, additive layer
manufacturing, layer manufacturing, solid freeform fabrication and freeform
fabrication.
• Definitions
– Additive manufacturing system includes additive manufacturing equipment,
machine and auxiliary equipment used for additive manufacturing.
– AM machine is section of the additive manufacturing system including
hardware, machine control software, required set-up software and peripheral
accessories necessary to complete a build cycle for producing parts.
– Feedstock is a material to be processed in an additive manufacturing system.
Categories of additive manufacturing processes
Additive
Manufacturing
Processes
Molten/Filament Powder Solid Layer

Liquid Processes
Processes Processes Processes
VAT
Material Extrusion Powder Bed Fusion Sheet Lamination
Photopolymerization
Material Jetting Binder Jetting
Directed Energy
Deposition
Categories of additive manufacturing processes
1. Vat photopolymerization is an additive manufacturing process in which

liquid photopolymer in a vat is selectively cured by light-activated
polymerization.
2. Material jetting is an additive manufacturing process in which droplets of
build material are selectively deposited.
3. Material extrusion is an additive manufacturing process in which material is
selectively dispensed through a nozzle or orifice.
4. Powder bed fusion is an additive manufacturing process in which thermal
energy selectively fuses regions of a powder bed.
5. Binder jetting is an additive manufacturing process in which a liquid
bonding agent is selectively deposited to join powder materials.
6. Directed energy deposition is an additive manufacturing process in which
focused thermal energy is used to fuse materials by melting as they are
being deposited.
7. Sheet lamination is an additive manufacturing process in which sheets of
material are bonded to form a part.
Additive manufacturing of polymers
ISO / ASTM52900 – 15 (Figure A1.3)
Additive manufacturing of metals
Additive manufacturing of ceramics
How does AM work?
https://youtu.be/yiUUZxp7bLQ
Additive manufacturing disciplines
• Engineering scope
Design, development, integration,
simulation, optimization
• Manufacturing scope
Technology, process, process
chain, post-processing
Quality
• Materials scope
Feedstock material, feedstock
characteristics
Engineering
• Quality scope
Process quality, product quality,
inspection and verification
Challenges in additive manufacturing
• The need for highly skilled operators

• High cost of AM equipment
• The need for post-processing
• High cost of feedstock materials
• AM processes are slower than mass production processes
• Inconsistent product quality, particularly with regard to part accuracy and
surface finishes
• Limitations of design tools for additive manufacturing
• Lack of process monitoring and control
• Lack of hardware and software necessary for multi-material deposition
• The layer-by-layer production causes anisotropy in mechanical properties
Phases of manufacturing technologies
Steps of AM process
Design for manufacturing
Design Process
Material DfM
Manufacturing
Selection Process
10 hours
0.06mm layer
80x85x110 mm
https://youtu.be/ZAdiVt2u0R8
Thank You

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MME 9651

Dr. Mostafa Yakout

Week Date Topic Due

1 Tue Sep 14, 2021 Introduction to Additive Manufacturing

6 Tue Oct 19, 2021 Concept of Vat Polymerization Project Presentation

• Additive Manufacturing (AM)

Molten/Filament Powder Solid Layer

Material Jetting Binder Jetting

1. Vat photopolymerization is an additive manufacturing process in which

ISO / ASTM52900 – 15 (Figure A1.3)

ISO / ASTM52900 – 15 (Figure A1.2)

ISO / ASTM52900 – 15 (Figure A1.4)

• The need for highly skilled operators

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