Additive manufacturing: technologies and materials

Additive manufacturing is understood as the process of growing products on a 3D

printer using a CAD model. This process is considered innovative and is opposed
to traditional methods of industrial production.

Today , the following additive manufacturing technologies can be distinguished:

 FDM (Fused deposition modeling) — the most common 3D printing

technology in the world. With its help, both cheap home printers and industrial
high-precision 3D printing systems are grown. The principle of construction
according to FDM technology consists in layer-by-layer growing of a product from
a pre-melted plastic thread.

The 3D model in STL format is transferred to the 3D printer software. The

program automatically (or the operator manually) places the model in the virtual
space of the working chamber. Then the program automatically generates elements
of auxiliary structures (from special support material) and calculates the amount of
consumables, as well as the time of growing the prototype. Before starting the
printing process, the model is automatically divided into horizontal layers and the
ways of moving the print head are calculated.
Then the process of direct 3D printing starts: a heating head with dies (extruder)
melts a thin plastic thread (fishing line) and layers it according to the data of a
mathematical 3D model.
After the completion of the product construction process, auxiliary structures are
removed (manually or dissolved in a special solution). The finished product can be
used in printed form or subjected to any post-processing method.
Examples of products created using FDM technology:

 SLM (Selective laser melting) is an innovative technology for the production of

complex products by laser melting of metal powder using mathematical CAD
models (3D metal printing). With the help of SLM, they create both precise metal
parts for working as part of assemblies and aggregates, and non-collapsible
structures that change geometry during operation.

The printing process begins with the separation of the digital 3D model of the
product into layers with a thickness of 20 to 100 microns in order to create a 2D
image of each layer of the product. The industry standard format is an STL file.
This file enters a special machine software, where the information is analyzed and
measured with the technical capabilities of the machine.
Based on the data obtained, the production cycle of construction is launched,
consisting of many cycles of building individual layers of the product.
The layer construction cycle consists of typical operations:
1) application of a powder layer of a given thickness (20-100 microns) on a
construction plate fixed on a heated construction platform;
2) scanning with a laser beam of the section of the product layer;
3) lowering the platform deep into the construction well by an amount
corresponding to the thickness of the construction layer.
The process of building products takes place in the SLM chamber of the machine
filled with inert gas argon or nitrogen (depending on the type of powder from
which the construction takes place), with its laminar flow. The main consumption
of inert gas occurs at the beginning of work, when the construction chamber is
purged, when air is completely removed from it (the permissible oxygen content is
less than 0.15%).
After construction, the product together with the plate is removed from the SLM
chamber of the machine, after which the product is separated from the plate
mechanically. Supports are removed from the constructed product, finishing of the
constructed product is performed.
 The almost complete absence of oxygen avoids the oxidation of consumables,
which makes it possible to print with materials such as titanium.

Examples of products created using SLM technology:

 Laser stereolithography (SLA) is a 3D printing technology based on the layer-

by-layer curing of a liquid material under the action of a laser beam.

A photopolymer is a substance that changes its properties under the influence of

ultraviolet light. In the normal state, the photopolymer is malleable, and when
exposed to UV radiation of the electromagnetic range, it acquires strength. The
duration of irradiation and the wavelength are calculated depending on the specific
material, the size of the object and environmental conditions.

A mesh platform is placed in a container with a liquid photopolymer, on which

the prototype will be grown. Initially, the platform is installed at such a depth that
it is covered by the thinnest layer of matter, only 0.05-0.13 mm thick — in fact,
this is the thickness of the layer in laser stereolithography. Next, a laser is turned
on, affecting those areas of the polymer that correspond to the walls of a given
object, causing them to solidify. After that, the entire platform is immersed in
exactly one layer, that is, to a depth of 0.05-0.13 mm.
Upon completion of the construction, the object is immersed in a bath with a
special composition to remove unnecessary elements and complete cleaning. And
finally, the final irradiation with light for the final solidification. Like many other
3D prototyping methods, SLA (laser stereolithography) requires the construction
of supporting structures, which are manually removed upon completion of
construction.

Examples of products created using SLA technology:

 MJM (Multi Jet Modeling) — multi-jet modeling using photopolymer or wax

material. This technology makes it possible to produce burnable or smelted master
models for casting, as well as prototypes of various products.

The principle of printing resembles an inkjet. The technology is based on a

printhead with a whole battery of tiny nozzles arranged linearly in several rows.
The number of nozzles starts from 96 for junior printer models and reaches 448 for
top models. One nozzle is one tiny drop of model material for building a product.
The printing unit moves along the working surface and applies a layer of liquid
polymer. The printed block is followed by a UV lamp, which illuminates the newly
applied particles of the material, as a result of which it hardens, forming a given
product.
In addition to the main material, an auxiliary (or support material) is used in the
printing process — VisiJet S300. This is a wax structure that serves as a support
for the hinged elements of the future model. After the end of printing, wax
supports are melted in a special furnace.

Examples of products created using MJM technology:

 PolyJet — 3D printing technology based on layer-by-layer curing of liquid

photopolymer material under the influence of ultraviolet radiation.

The 3D printer's printing unit sprays the model material and the support material
in thin layers (16/30 microns), according to the data of the mathematical 3D model.
Each layer is polymerized by the light of an ultraviolet lamp immediately after
application. The result is an object that does not require any additional surface
treatment. A model printed using PolyJet technology can be used immediately after
the printing process is completed.

Support material:
In the process of building complex products, there are often various cavities,
overhanging structures. To prevent their collapse, all voids under such elements are
filled with a special material - a support material. In addition, this material serves
as an additional insurance when printing thin walls and complex structures.

Examples of products created using PolyJet technology:

 CJP (Color jet printing) — is a 3D printing technology based on layer-by-

layer bonding and coloring of composite powder based on gypsum or plastic.
 The 3D printer using CAP technology consists of two parts: a product
construction chamber, into which the model material is loaded, and a cleaning
chamber, where excess material is removed.
The production of the prototype takes place in layers. First, the model material is
evenly distributed in a thin layer over the entire plane of the construction camera
platform. Then a binder is applied to this layer, gluing and coloring the material
particles together according to a 3D computer model.
After applying the adhesive, the platform moves down by the thickness of the
layer (0.1016 mm). After the offset, the print head starts its programmed
movement again, growing the model layer by layer.

Examples of products created using CJP technology: