Additive Manufacturing

N. Sinha
Department of Mechanical Engineering
IIT Kanpur
Introduction

Source: HASBRO/MB Puzzle

 Introduction
Principle
Add layers of material one at a time to build the solid
part from bottom to top
 Definition
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.
(from the International Committee F42 for Additive
Manufacturing Technologies, ASTM)..

What You See Is What You Build (WYSIWYB) Process

Alternative Names
Evolution

Source: Royal Academy of Engineering

Growing 3D Printed Market
Where Additive Manufacturing is being used?
AM Levels

Source: Gebhardt, Additive Manufacturing

 AM Levels
Solid imaging or concept modelling: It defines a family of parts that are applied to
verify a basic concept. The parts resemble a three dimensional picture or a statue.
They are used just to get a spatial impression in order to judge the general
appearance and the proportions.

Functional Prototyping: It is applied to allow checking and verifying one or more

isolated functions of the later product or to make the production decision, even though
the model cannot be used as a final part.

Rapid Manufacturing: It summarizes all processes that deliver final products or final
parts that need to be assembled to become a product. An AM part is called a product
or final part, if it shows all characteristics and functions that are allocated to it during
the product development process. If the resulting part is a positive, the process is
called “Direct Manufacturing”, if it is a negative, which means a die, a mold or a
gauge, it is named “Direct Tooling”.

Prototype Tooling: If just a few parts are needed or details are changed frequently, a
temporary mold made from substitute material is typically sufficient. This kind of mold
shows the quality of functional prototypes but meets, at least partially, the direct
tooling application level. The corresponding application level is some kind of an
intermediate level between rapid prototyping and rapid manufacturing.
Market Segments
Generic AM Process

Source: Gibson, Additive Manufacturing

 Step 1: Conceptualization and CAD
 AM parts must start from a 3D model
 CAD solid modelling software (e.g., ProE)
 Reverse engineering equipment (e.g., laser scanner)
Step 1: Conceptualization and CAD
 Introduction to Reverse Engineering
The primary input for AM is CAD file/model.
Suppose that for a part (to be copied, modified or
repaired)
 CAD was not used in the original design;
 there is inadequate documentation on the original
design;
 the original CAD model is not sufficient to support
modification or manufacturing using modern methods;
 the original supplier is unable or unwilling to provide
additional parts.
 Introduction to Reverse Engineering
“Examining competitive or similar or prior products in great
detail by dissecting them or literally taking them apart.”
- Dym & Little

Technological principles of a device through analysis of its

structure, function and operation.

“What does this do?”

“How does it do that?”
“Why would you want to do that?”
 Introduction to Reverse Engineering
Purposes solved
 Dissection and analysis
 Experience and knowledge for an individual’s personal
database
 Competitive benchmarking
Step 1: Data Acquisitions Techniques for CAD

Cast a beam onto the object surface and then inspect the reflected beam using a
sensor that is placed coaxial to the source.
 Introduction to Reverse Engineering
Reverse Engineering Process
1. Digitizing the parts
This step uses a reverse engineering device to collect raw
geometry of the object.
The data is usually in the form of coordinate points of
the object relative to a local coordinate system.
2. Building CAD models
This step converts the raw point data obtained from step
1 into a usable format.

Physical part
Physical part CAD model
Physical part Prototype
Physical partpart
Example
 Step 2: Conversion to STL
 CAD data files must be translated into a format, which can be
interpreted by the 3D printing machine
 3D Systems had to develop an interface between CAD systems
and their machine and developed a file format “stl”, derived
from STereoLithography
 STL is de facto standard format supported by CAD programs
and other 3D printing machines
 Approximate the surfaces of the model with a series of
triangular facets
 Errors may occur during the approximation phase
STL File- ASCII Format
A Facet in STL File
 STL File
Advantages
(i) Provides a simple method of representing 3D CAD data
(ii) A de facto standard and has been used by most CAD systems and
RP systems
(iii) It can provide small and accurate files for data transfer for certain
shapes

Disadvantages
(i) The STL file is many times larger than the original CAD data file
(ii) The geometry flaws exist in the STL file
(iii) The subsequent slicing of large STL files can take many hours
Accuracy Control
Step 3: Transfer to AM Machine and STL
File Manipulation
 Data preparation:
 Determination of build-up direction
 Scaling and positioning
 Packing
 Support generation
 Slicing and path planning
Determination of Build-up direction
 Accuracy
 Build-up speed
 Trapped volume
 Necessity of support structure
 Support Structures

 Facets whose normal are in a certain angle relative to

build-up direction;
 Facets facing downward with material above them
Slicing and Path Planning
 Step 4: Machine Setup

 Energy source
 Timing
 Material constraints
 Warming up (FDM, SLS)
 Step 5: Build

 Automated process
 Iterative process
 Little human interaction:
 Running out of material, power
 Software glitches
 Step 6: Removal and Cleanup
 Part must be either separated from a build platform or
removed from excess build material surrounding it
 Remove support material
 Safety:
 Toxic or hazardous material
 High temperature
 High power laser
 Step 7: Post-process
 Part finishing: polishing, sandpapering, machining
 Coatings or infiltration to strengthen the part
 Overcuring
 Painting
Step 8: Application

Source: Gibson, Additive Manufacturing

Additive vs Subtractive Manufacturing
 Additive vs Subtractive Manufacturing

Figure: Features that represent problems using CNC machining.

Source: Gibson, Additive Manufacturing

 Additive vs Forming Manufacturing

Expensive tools are typically required for the forming processes

 Benefits

Source: SAVING project/Crucible Industrial Design Ltd.; Roland Berger

Benefits

Source: Roland Berger

Benefits

Source: Roland Berger

 Future: Home Manufacturing
Customization:
•Bristle hardness
•Colour
Old toothbrush •Handle Style and shape
•Etc.
New toothbrush

Laser scanner to input

personalized data

Home 3D Printer
Case Studies

Source: Royal Academy of Engineering

 AM Unique Capabilities
 Shape complexity: it is possible to build virtually any shape
 Hierarchical complexity: features can be designed with shape
complexity across multiple size scales

Various types of nano/microstructures

can be achieved by careful control of the
process parameters (e.g. laser power, scan
rate) for a particular material, and can
vary from point to point within a
structure.

The ability to simultaneously control a part's nano/microstructure,

mesostructure, and macrostructure simply by changing process
parameters and CAD data is a capablity of AM which is unparalleled
using conventional manufacturing.
Principle 1: Complexity is Free
Principle 2: Zero Constraints
Principle 3: Variety is Free
 AM Unique Capabilities
 Functional complexity: functional devices (not just individual
piece-parts) can be produced in one build
 Material complexity: material can be processed one point, or
one layer, at a time as a single material or as a combination of
materials
 When building parts in an additive manner, one always has access to
the inside of the part.
 Component can be inserted and it is possible to fabricate operational
mechanisms in some AM processes.

Pulley-driven snake-like robot

Source: Gibson.
Principle 4: No Assembly Required
Principle 5: Infinite Shades of Materials
 AM Unique Capabilities
However, manufacturing useful parts from these materials often has been
problematic.
Example: Turbine blade for a jet engine
I. The outside of the blade must be resistant to high temperature and very
stiff to prevent elongation;
II. The blade root must be ductile and has high fatigue life;
III. Blade interiors must have high heat conductivity so that the blades can be
cooled.
A part with complex shape that requires different material properties in
different regions.
No single material is ideal for this range of properties.

A significant issue hindering the adoption of AM’s material complexity

is the lack of design and CAD tools that enable representation and
reasoning with multiple materials.
 Functionally Graded Materials (FGMs)
The concept of functionally graded materials, or heterogeneous materials, has received
considerable attention.

FGMs can be obtained by

layered mixing of two
materials of different thermo-
mechanical properties with
different volume ratio by
gradual changing from layer
to layer.
Principle 6: Zero Lead Time
Principle 7: Zero Skill Manufacturing
Principle 8: Compact & Portable Manufacturing
Principle 9: Less Waste By-product
Principle 10: Precise Replication