Additive Manufacturing

MMT 558
Lecture -2
Introduction to Additive Manufacturing
Dr. Manjesh Kumar
Assistant Professor
Department of Mechanical Engineering
SRM University AP
Andhra Pradesh ‒ 522502, India
Contact No. +918100804553
Email : manjesh.k@srmap.edu.in,
phdmanjesh@gmail.com 1
 2
Contents

❑ Term of Reference
o Definitions
❑ Capabilities of Additive Manufacturing
o Geometric Capabilities
o Material Capabilities
❑ Classification of Additive Manufacturing
o ASTM
o Based on Type of Raw Stock Material
 3
Introduction to AM
Term of Reference
3D 3D Printing Stereolithography

Additive Layer Manufacturing (ALM),

AM Additive Manufacturing Additive Digital Manufacturing (ADM)

Layer Based Manufacturing,

LM Layer Manufacturing Layer Oriented Manufacturing,

SFF Solid Freeform Fabrication

DM Digital Manufacturing Digital Mock-Up

RP Rapid Prototyping/Tooling/Manufacturing
Direct Manufacturing,
Direct Tooling
 4
Introduction to AM
Term of Reference: 3D Printing
The term 3D Printing is as easy and simple as 2D printing.

2D printer 3D printer
 Introduction to AM 5

Term of Reference
3D 3D Printing Stereolithography

Additive Layer Manufacturing (ALM),

AM Additive Manufacturing Additive Digital Manufacturing (ADM)

Layer Based Manufacturing,

LM Layer Manufacturing Layer Oriented Manufacturing,

SFF Solid Freeform Fabrication

DM Digital Manufacturing Digital Mock-Up

RP Rapid Prototyping/Tooling/Manufacturing
Direct Manufacturing,
Direct Tooling
 Introduction to AM 6

Term of Reference: Additive Manufacturing

“Additive Manufacturing” refers to the layer-by-layer fabrication
of three-dimensional physical models directly from computer- Pre-process(tessellate, slice,
aided design (CAD). It is an automatic process of manufacturing support)
objects (parts, prototypes, tools and even assemblies) directly
from their CAD models without any cutters, tools or fixtures
specific to the object geometry.
Build part
(additive/stacking)

CAD file STL file Sliced file

Post-process (break
support, finish)
 Introduction to AM 7

Term of Reference
3D 3D Printing Stereolithography

Additive Layer Manufacturing (ALM),

AM Additive Manufacturing Additive Digital Manufacturing (ADM)

Layer Based Manufacturing,

LM Layer Manufacturing Layer Oriented Manufacturing,

SFF Solid Freeform Fabrication

DM Digital Manufacturing Digital Mock-Up

RP Rapid Prototyping/Tooling/Manufacturing
Direct Manufacturing,
Direct Tooling
 Introduction to AM 8

Term of Reference
3D 3D Printing Stereolithography

Additive Layer Manufacturing (ALM),

AM Additive Manufacturing Additive Digital Manufacturing (ADM)

Layer Based Manufacturing,

LM Layer Manufacturing Layer Oriented Manufacturing,

SFF Solid Freeform Fabrication

DM Digital Manufacturing Digital Mock-Up

RP Rapid Prototyping/Tooling/Manufacturing
Direct Manufacturing,
Direct Tooling
 Introduction to AM 9

Term of Reference: Digital Manufacturing

DM are the set of technologies those can reduce the product development time and cost as well as
capable of addressing the need for customization, increased product quality, and faster response
to the market.* A Manufacturing Technology can be called as Digital manufacturing if it is centered
around a computer system.→ AM technologies fulfill this criterion.

Generic method of Additive Manufacturing (Liou, 2008)

* Chryssolouris, George, et al. "Digital manufacturing: history, perspectives, and outlook." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering
Manufacture 223.5 (2009): 451-462.
 Introduction to AM 10

Term of Reference: Digital Manufacturing

Like a digital image is composed of picture elements,
also known as pixels. The same analogy is can be
extended for STLs.

This format uses a series of linked triangles to

recreate or reproduce surface geometry of
the 3D model. The more triangles used, the higher
resolution the 3D model will have. STL file is
widely used because it is simple, light and easy to be
handled by 3D machines and software.
Also, the objects are fabricated by joining the thin
layers by a suitable method therefore the method
of producing the product is generic and
completely automatic.
 Introduction to AM 11

Term of Reference
3D 3D Printing Stereolithography

Additive Layer Manufacturing (ALM),

AM Additive Manufacturing Additive Digital Manufacturing (ADM)

Layer Based Manufacturing,

LM Layer Manufacturing Layer Oriented Manufacturing,

SFF Solid Freeform Fabrication

DM Digital Manufacturing Digital Mock-Up

RP Rapid Prototyping/Tooling/Manufacturing
Direct Manufacturing,
Direct Tooling
 Introduction to AM 12

Term of Reference: Rapid Prototyping/Tooling/Manufacturing

Definition of
product Complete
CAD of
a car

Final product
Concept design Accurate
and evaluation
Sketch of
Iterate

a Car
Foam model
Design analysis of a car
Physical
Virtual

Prototype

3D CAD model and design Rough

documentation Component
Concept design Primary design Detailed design Detailed for mfg 13
(DFM)

Simulate realistic Simulate

appearance functionality Simulate mfg
process
Virtual Reality (VR)

Virtual Prototyping (VP)

CAD Physical model

3D geometry model

Rapid Prototyping (RP)

3D geometry model
Rapid Tooling (RT)

RE, CT, MRI

Manufacturing (RM ?)
Available Object
 M01 L01: Contents 14

❑ Term of Reference
o Definitions
❑ Capabilities of Additive Manufacturing
o Geometric Capabilities
o Material Capabilities
❑ Classification of Additive Manufacturing
o ASTM
o Based on Type of Raw Stock Material
 Introduction to AM 15

Capabilities
“Additive Manufacturing” refers to the layer-by-layer fabrication of three-dimensional physical
models directly from computer-aided design (CAD). It is an automatic process of manufacturing
objects (parts, prototypes, tools and even assemblies) directly from their CAD models without
any cutters, tools or fixtures specific to the object geometry.

Geometric Capabilities Material Capabilities

Objects of any kind of geometric (direct assemblies, conformal, custom, complex) or material (any
variety – poly/metal/ceramic, non-equilibrium, gradient – mono/composite/gradient, porous/lattice,
soft/hard) complexity can be produced.
 Introduction to AM 16

Capabilities: Geometric Capabilities

Direct assembly
 Introduction to AM 17

Capabilities: Geometric Capabilities

Conformal cooling channel

 Introduction to AM 18

Capabilities: Geometric Capabilities

Mass customization
 Introduction to AM 19

Capabilities: Geometric Capabilities

Density-based FGM through AM

Complex lattice structures

 Introduction to AM 20

Capabilities: Material Capabilities: Non Metals

• Photopolymer
• Acrylate Resin
• Bio-based Acrylate • Dicalcium phosphate anhydrous
• Polystyrene, Polyamides calcium carbonate
• Thermoplastic polymers • Silica (SiO2),calcium carbonate
• Acrylonitrile-Butadiene-Styrene (CaCO3)
Polymers (ABS) • Calcium silicate
and • Poly-Carbonate (PC) Ceramics • Eggshell
Composites • Polylactic Acid (PLA) • Akermanite
• Nylon6 based Nano Composite • Alumina ceramic with CaSo4 and
• Carbon fiber reinforced PLA dextrin
• Fibre reinforced hydrogel • Ceramic Matrix Composite
• Alumina powder reinforced • Polymer derived ceramic
polymer matrix
• Glass fiber reinforced polymer
 Introduction to AM 21

Capabilities: Material Capabilities: Non Metals

• Cement
• Concrete
Construction • Fiber reinforced concrete
• Portland cement and calcium aluminate
• Polymer Foam

• Bioinks
• Cell-laden hydrogels
• Cell/ tissue spheroids
• Decellularized Matrix Components
Biomaterials and Food • Drugs and Pharmaceutical Materials
• Acetaminophen
• Anhydrous Theophylline
• Caffeine
• Chocolate, Dough, Cheese, Powdered Sugar,
Sauce, etc.
 Introduction to AM 22

Capabilities: Material Capabilities: Metals

• Copper
Pure • CoCrCuFeNiAl
• Gold
Metals
• Titanium • CoCrCuFeNiAl
High Entropy Ti
Alloys • CoCrFeNi
• Ti6Al4V • ZrTiVCrFeNi
• SS 316L • TiZrNbMoV
• Austenitic stainless steel
• Maraging steel
• Precipitation hardenable stainless
Metal steels
Alloys • H13 Tool Steel • Fe-V
• AlSi10Mg • Ni-Fe-Mo
• AlSi12 Magnetic Alloys
• Fe-30%Ni
• Inconel 625 (IN-625) • Fe-Si-B-Cu-Nb
• Inconel 718 (IN-718)
• WC-12%Co
 Introduction to AM 23

Capabilities: Material Capabilities

Functionally Graded Material (FGMs)

 Introduction to AM 24

Capabilities: Material Capabilities

Colourful Object
 Introduction to AM 25

Capabilities: Material Capabilities

3D Printing Spatially Varying Color and Translucency

A. Brunton, C.A.N.A. Arikan, T.M. Tanksale, F. Igd, 3D Printing Spatially Varying Color and Translucency, 37 (2018)
 M01 L01: Contents 26

❑ Term of Reference
o Definitions
❑ Capabilities of Additive Manufacturing
o Geometric Capabilities
o Material Capabilities
❑ Classification of Additive Manufacturing
o ASTM
o Based on Type of Raw Stock Material
 Introduction to AM 27

Classification: ASTM

1 Vat Photopolymerization
5 Sheet Lamination

2 Material Jetting

6 Powder Bed Fusion

3 Binder Jetting

7 Directed Energy Deposition

4 Material Extrusion
 Introduction to AM 28

Classification: ASTM: Vat Polymerization

 Introduction to AM 29

Classification: ASTM: Material Jetting

 Introduction to AM 30

Classification: ASTM: Binder Jetting

 Introduction to AM 31

Classification: ASTM: Material Extrusion

 Introduction to AM 32

Classification: ASTM: Sheet Lamination

 Introduction to AM 33

Classification: ASTM: Powder Bed Fusion

 Introduction to AM 34

Classification: ASTM: Directed Energy Deposition

 Introduction to AM 35

Classification: ASTM

Vat Photo Material

Material Jetting Binder Jetting Sheet Lamination
Polymerization Extrusion

ASTM categorizes 7 basic AM processes

Multiple variations of these 7 AM processes exists the
core idea is same
Powder Bed Direct Energy
Fusion Deposition
 Introduction to AM 36

Classification: Based on Raw Material

Type of Raw-stock

Liquid Solid Gas

Not Yet

Rapid
Photopolymer
Freezing
SLA RF

Sheet Powder Wire

LOM 3DP, SLS, DED FDM, WAAM
 Course Structure 37

Fundamentals of Additive Manufacturing

M1 Introduction to Additive Manufacturing

M2 Computer Aided Process Planning for Additive Manufacturing

M3 Liquid Additive Manufacturing

M4 Sheet Additive Manufacturing

Live Demonstration of M5 Wire Additive Manufacturing

5 AM Technologies

M6 Powder Additive Manufacturing

Thank You