UNIT I Introduction

Additive Manufacturing (AM)

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

Need of Additive Manufacturing (AM)

Create parts with greater complexity
Additive manufacturing can overcome the limitations of traditional manufacturing
methods to create highly complex parts with improved functionality.
Minimal material waste
With the new design possibilities afforded by 3D printing, engineers can produce
lightweight parts in part by optimising the distribution of material, leading to substantial
material savings.
Simplified assembly
Part consolidation is another game-changing design benefit of additive manufacturing.
With traditional manufacturing, multiple components must be produced and then
subsequently assembled to create the final part.
Material innovation
Advancements in materials research have led to the exciting development of new
materials. Consequently, unique 3D printing materials have been developed that would be
difficult to machine or mould, such as TPU filaments and metal superalloys powders).
Cost-effective customization
3D printing enables quick and multiple design iterations at no extra cost, taking
customization possibilities to new heights. And as additive manufacturing creates parts
directly from digital files, the manufacturing process is significantly accelerated. This means
that companies can produce customized products much faster and cost-effectively.
Minimum support structures
Part orientation is one of the key benefits when designing for additive manufacturing.
Choosing the correct part orientation during the design stage can reduce the printing and post-
processing time whilst minimizing the need for support. In spite of the fact that support
structures are virtually a necessity for many complex 3D printed parts, it is ideal to design
parts with as few support as possible, as this will make post-processing easier, saving you
time and material.

Additive Manufacturing Process Chain

From CAD description to physical result, AM involves several steps. The process will
vary depending on the product. It is likely that smaller, simpler products make use of AM
only for visualization purposes, whereas larger, more complex products may incorporate AM
at multiple stages and iterations throughout the development process. Also, in the early stages
of product development, rough parts may be needed, and AM is generally used due to its
rapid fabrication capability. As parts advance through the process, they may need cleaning
and post-processing (such as coating and sanding) before they can be used; in this regard,
rapid prototyping is useful due to the complexity of forms that can be created without
involving tooling.
Step 1: CAD
CAD models that fully describe the external geometry are required for all AM parts.
Any professional CAD solid modelling software can be used to create this, but the final
product must be a 3D solid or surface model. To create such an image, reverse engineering
equipment (for example, laser and optical scanning) can also be used.
Step 2: Conversion to STL
Upon completion of the digital model, the STL (Standard Tessellation Language) file
format must be used to create the stereolithography. Nearly every CAD system supports this
format, which is how AM machines communicate. The STL file serves as the basis for
calculating the slices of the model.
Step 3: Transfer to Machine
In the third step, the STL file is transmitted to the AM machine. As a result of this
step, it is possible to adjust the build so that it is positioned and sized correctly. A computer
controls the AM machine. The AM machine is controlled by the computer, that computer only
generates the required instruction in the form of G-codes and M-codes based on the given
process parameters. It generates instructions automatically, if any correction is needed for the
betterment of the part to be built it can be corrected.
Step 4: Setup
Before the building starts, the equipment has to be set up. The settings can constitute
power, speed, layer thickness, and other several parameters related to material and process
constraints, etc.
Step 5: Build
The fifth step is the actual building of the CAD model, melting layer by layer. This
process can be semi or fully automated but some online monitoring is often conducted, so
that the machine does not run out of material or that some software error occurs.
Step 6: Part Removal
Once the part is manufactured it has to be removed from the process, which is
normally done manually. This may require interaction with the machine, which may have
safety interlocks to ensure, for example, that the operating temperatures are sufficiently low
or that there are no actively moving parts.
Step 7: Post-processing
After the build, the part might need some post-processing before it is completely
finished. Of course, depending on the material and AM process used, some parts might need
machining, cleaning, polishing, removal of support structures, hot isostatic pressing (HIP),
and heat treatments.
Step 8: Application
At this stage, the part can be ready for use. Nevertheless, it could also need some
additional treatments, like painting, or assembling with other components before it is fully
usable. For example, they may require priming and painting to give an acceptable surface
texture and finish. Treatments may be laborious and lengthy if the finishing requirements are
very demanding. They may also be required to be assembled with other mechanical or
electronic components to form a final model or product.

Additive Manufacturing in Product Development Processes

Additive manufacturing has transformative potential to revolutionize manufacturing
and take it to new heights of production and efficiency. For the time being, however, it’s an
approach still rife with unanswered questions.
Manufacturers want to experiment with additive manufacturing, but they might
wonder whether it’s scalable enough to meet present and future volume demands.
Additionally, they’re concerned about how many 3D printers it will take to satisfy production
quotas — and whether those printers can consistently meet quality standards. Overall,
product developers assess their strategic objectives and try to determine how much value
additive manufacturing actually provides.
We can’t expect just those innovations to appear on their own — or for additive
manufacturing to mature without a lot of effort. We also can’t expect manufacturers still
questioning 3D printers to embrace them without some certainty the effort will pay off. With
that in mind, use these three strategies to manage the development of products that use
additive manufacturing.
1 Build process-focused teams rather than product-focused ones. Consider
rearranging personnel teams to focus on manufacturing processes rather than specific
products. Lay out manufacturing plans for different products, see which ones can incorporate
3D printing, and create teams that support the necessary technologies rather than have
specific ownership of given products.
2 Devote time to part validation. Give equal consideration to the
qualification/certification of additive-manufactured parts, especially for critical applications.
Start by considering the viability of building various parts with 3D printers. If you can build
them, weigh whether using a 3D printer would be cheaper or more efficient than conventional
approaches. Finally, ask whether the quality of 3D-printed parts will be as good as — or
better than — conventional processes.
This goes back to the developing standards and certifications for additive
manufacturing in many industries (particularly aerospace). Strict quality controls haven’t
been a priority absent those standards, but those quality controls are necessary and likely
coming shortly. Manufacturers can get ahead of this issue by considering the complete
triangle — viability, efficiency, and quality.
3 Conduct “virtual prototype testing.” This testing will help reduce blind alley
designs by keeping nonviable designs restricted to the drawing board. With a virtual
prototype test software, digital design files can be tested with different materials to help
determine whether each design is feasible.
Different types of additive manufacturing have different strengths and weaknesses.
Concluding whether one or another is suitable for product development isn’t a simple
process. Virtual prototyping avoids unnecessary waste and helps manufacturers uncover
every opportunity to leverage additive manufacturing applications and innovations as they
continue to develop.

Virtual Prototyping
Virtual prototyping, often known as VP, is a software-based engineering discipline
which involves modelling a system, simulating and visualising its behaviour under real-world
operating conditions, and refining its design through an iterative process. VP is increasingly
used as a substitute for rapid prototyping.
Virtual prototypes enable early software development, reducing the total time
necessary to develop and test new products in what is now known as a “shift left” approach.
Virtual prototyping is a method in the process of product development. It involves
using computer-aided design (CAD), computer-automated design (CAutoD) and computer-
aided engineering (CAE) software to validate a design before committing to making a
physical prototype. This is done by creating (usually 3D) computer generated geometrical
shapes (parts) and either combining them into an "assembly" and testing different mechanical
motions, fit and function. The assembly or individual parts could be opened in CAE software
to simulate the behavior of the product in the real world.
Rapid Tooling
Rapid tooling is an umbrella term that refers to any process that allows you to make a
tool or mold in a short amount of time. It is generally faster and more streamlined than
conventional tooling.
Rapid Tooling VS Rapid Prototyping
Rapid Tooling is any method or technology that enables rapid production of parts, which will
function as a tool (primarily die or mold). In manufacturing industry, one of the most
common Rapid Tooling methods - Injection Mold Tooling is utilized as Rapid Tooling
channel to produce injection-molded parts quickly and inexpensively.
Rapid Prototyping refers to any method or technology that enables rapid fabrication of a
physical part that could be used as a prototype or end-use functional product. Common types
of Rapid Prototyping technology are as following:
 (I) Additive Manufacturing (3D printing)
 (II) Subtractive Manufacturing (CNC Machining)
For entrepreneurs or small business looking to get their ideas on the market fast, Rapid
Tooling and Rapid Prototyping are particularly the best and quickest way for new product
development in comparison to conventional manufacturing method.
Benefits of Rapid Tooling
1. Faster Time to Market
In conventional tooling method, multiple manufacturing processes and techniques might be
involved in product development cycle. This may increase the time spending on each step and
extend the time from design turning into a real product. Rapid Tooling involves fewer steps
than conventional tooling method. Rapid Tooling enables speeding up the whole process. The
faster you can get through the prototyping and molding process, the sooner you can finalize
your design and get it into the customers’ hand.
2. Lower Cost
The longer time spending on product development cycle, the greater the cost will be. The
Rapid Tooling advantage of speed could save your business money over time.
3. Variety of Material Grades
Rapid Tooling allows you to use the actual production grades of material. You can use Rapid
Tooling to fabricate custom mold quickly. You can then produce as many prototypes from this
mold as you can, creating parts with different material grades and test on their properties.
This will allow you to have a clearer picture on which material grade performs best in real
world application and allow you to make the correct material selection before launching the
new product in the market.
4. Designs and Functionality Testing
Rapid Tooling allows the mold to be fabricated in a short timeframe. Hence, this provides
more freedom to test out the new ideas and make design adjustments. The parts can be
mechanical tested such as impact and stress testing to explore the design flaws before
production. This will massively prevent a lot of issues arisen during the future high volume
production stage.
5. Process Parameter Testing
Rapid Tooling can also be used to test the process parameter during production stage. For
example, different injection speed and mold temperature for injection molding process will
affect the part quality. In this way, the engineers and designers could have more measure
control on the final part.

Classification of Additive Manufacturing Process