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Edited by
Amit Bandyopadhyay
Susmita Bose
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
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have been made to publish reliable data and information, but the author and publisher cannot assume
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to copyright holders if permission to publish in this form has not been obtained. If any copyright material
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Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are
used only for identification and explanation without intent to infringe.
v
vi Contents
Index....................................................................................................................... 463
Preface
The field of additive manufacturing is seeing an explosive growth in recent years
due to renewed interest in manufacturing in the United States and other parts of the
world. The experience of drawing something in a computer and then see that part
being printed in a 3D printer, which can be touched or felt, is still fascinating to
many of us. Now we are seeing the same in our kids who are only in their middle
school or high school and experience the revolution of additive manufacturing/3D
printing through their own creation. Such transformative change in our society is
only possible due to significant reduction in the price of various 3D printers. Even a
few years back, a good 3D printer was more than $50,000 in the United States. Due
to the high cost of 3D printers, the majority of our population was only able to see
a picture or a video of different 3D printers. As the cost of the printer came down
below $1000, most businesses, universities and schools now have some kind of 3D
printers, which allows many people to explore and innovate with this fascinating
technology. Therefore, we felt that our book will be quite timely where we have tried
to capture some of these fascinating developments using “3D Printing” or “Additive
Manufacturing” technologies.
We understand that there are a few other books in the market that deal with addi-
tive manufacturing in some form. When we reviewed the landscape, we realized
that majority of those books are developed with greater emphasis on mechanical
engineering aspects. However, at present, most of the printing technology is quite
mature and majority of the innovation is coming in the areas of materials develop-
ment, related critical issues and their applications. Therefore, we have focused our
work more in the applications of additive manufacturing than the core 3D printing
technologies. Our hope is that the reader will be able to see how these technologies
are currently being used and then contribute to the field with their own innovation.
We have designed the book in a way that can also be used in a class room setting.
The first few chapters are focused on different additive manufacturing technolo-
gies based on various materials that are typically used. Then we discuss some of
the application areas where additive manufacturing is making a significant impact.
Finally, some discussions on educational aspects and regulatory issues have also
been added since those are becoming important as the additive manufacturing is
becoming a more mature technological platform in many industries. For this Second
Edition, we have more emphasis on design issues in additive manufacturing and new
information related to first-generation additive manufacturing processes for poly-
mers. We have also added suggested further reading materials and some questions
for educators if used as a textbook.
We like to thank all the authors for their contributions in this book. Without their
help our project would have never been completed. Also, without some sacrifice at
home from both our boys, Shohom and Aditya, we could not have completed this
work.
Even after working in this area for more than 20 years, we still learn new things
regularly related to applications of additive manufacturing. We hope that this book
vii
viii Preface
will be useful to many veteran researchers as well as those who are entering this field
now, and help them understand the subject better to contribute toward their work,
which can make a positive difference in our society.
Susmita Bose is Herman and Brita Lindholm Endowed Chair Professor in the School
of Mechanical and Materials Engineering (MME) at Washington State University.
Professor Bose received her BS from Kalyani University (India), MS from the Indian
Institute of Technology (IIT)—Kanpur, and PhD from Rutgers University (NJ, USA)
in 1998 in Physical Organic Chemistry. Since 1998, she is working with 3D printing of
bone tissue engineering scaffolds with controlled chemistry, especially with calcium
phosphates, surface modification of metallic implants, and drug delivery. In 2001, she
started as an assistant professor in MME, promoted to associate professor in 2006,
and to full professor in 2010. Her awards include the Presidential Early Career Award
for Scientist and Engineers (PECASE, the highest honor given to a young scientist by
the US President at the White House) award from the National Science Foundation,
the Schwartzwalder-Professional Achievement in Ceramic Engineering award, and
Richard M. Fulrath award from the American Ceramic Society (ACerS). Prof. Bose
was named as Life Science Innovation Northwest Women to Watch Honoree by the
Washington Biotechnology and Biomedical Association. She has supervised over 40
graduate students, published over 250 technical papers, edited 9 books, and inventor
of 11 issued patents. Her research papers have been cited over 16,000 times (“H” index
68, Google Scholar, 09/2019). Dr. Bose is a fellow of the Materials Research Society,
US National Academy of Inventors, the American Society for Materials, the American
ix
x Editors
Association for the Advancement of Science, the Royal Society for Chemistry, the
Washington State Academy of Sciences, the American Institute for Medical, and
Biological Engineering and the ACerS. Dr. Bose’s group research on 3D printed bone
tissue engineering scaffolds has been featured by the AP, BBC, NPR, CBS News,
MSNBC, ABC News, and many other TV, radio stations, magazines, and news sites
all over the world.
Contributors
Vamsi Krishna Balla Mitun Das
Bioceramics and Coating Division Bioceramics and Coating Division
CSIR – Central Glass & Ceramic CSIR – Central Glass & Ceramic
Research Institute Research Institute
Kolkata, India Kolkata, India
xi
xii Contributors
Dongxu Ke M. J. Mirzaali
W. M. Keck Biomedical Materials Department of Biomechanical
Research Lab Engineering
School of Mechanical and Materials Faculty of Mechanical, Maritime, and
Engineering Materials Engineering
Washington State University Delft University of Technology (TU
Pullman, Washington Delft)
Delft, the Netherlands
Bahattin Koc
Faculty of Engineering and Natural Bryan Morrison
Sciences One Patient Solutions
Department of Manufacturing and Biomet Inc.
Industrial Engineering Warsaw, Indiana
Sabanci University
Istanbul, Turkey S. Burce Ozler
Department of Manufacturing and
Caitlin Koski Industrial Engineering
School of Mechanical and Materials Sabanci University
Engineering Istanbul, Turkey
Washington State University
Pullman, Washington Dishit Paresh Parekh
Department of Chemical and
Can Kucukgul Biomolecular Engineering
Department of Manufacturing and North Carolina State University
Industrial Engineering Raleigh, North Carolina
Sabanci University
Istanbul, Turkey Clark Patterson
Rapid prototype+manufacturing
Mukesh Kumar (RP+M)
Advanced Process Technology Group Avon Lake, Ohio
Biomet Inc.
Warsaw, Indiana Naboneeta Sarkar
W. M. Keck Biomedical Materials
Y. Li Research Lab
Department of Biomechanical School of Mechanical and Materials
Engineering Engineering
Faculty of Mechanical, Maritime, and Washington State University
Materials Engineering Pullman, Washington
Delft University of Technology (TU
Delft)
Delft, the Netherlands
Contributors xiii
CONTENTS
1.1 Introduction.......................................................................................................2
1.2 History of AM...................................................................................................2
1.2.1 Start of 3D Printing...............................................................................2
1.2.2 Development of Other RP Technologies...............................................3
1.2.3 Moving from RP to AM........................................................................4
1.2.4 Impact of AM........................................................................................5
1.3 Current Manufacturing Challenges...................................................................6
1.3.1 Part-versus Systems-Level Manufacturing............................................6
1.3.2 Centralized and Projection-Based Manufacturing Issues.....................7
1.3.3 Generalized Designs: Consumer Settling for Only Adequate
Products������������������������������������������������������������������������������������������������8
1.4 AM: Unparalleled Manufacturing Paradigm....................................................9
1.4.1 Current State of AM and How It Generally Works...............................9
1.4.2 Advantages of AM: No Restriction on Design......................................9
1.4.3 Advantages of AM: Versatility in Manufacturing............................... 10
1.4.4 Advantages of AM: Altering Materials for Enhanced Performance..... 11
1.4.5 AM Already Incorporated into Modern Manufacturing..................... 11
1.4.6 Evolution of CAD to AM and Its Influence on Manufacturing........... 12
1.5 Global Engineering and AM........................................................................... 13
1.5.1 Moving from Localized to Globalized Engineering........................... 13
1.5.2 Engineer from Anywhere in the World Efficiently and Effectively....... 14
1.5.3 Manufacturing in Space: No Longer a Dream.................................... 14
1.6 Future Trends................................................................................................... 15
1.6.1 On-Demand Manufacturing of Custom Products............................... 15
1.6.2 Allowing People’s Creativity to Become a Reality............................. 16
1.6.3 Personal AM Machines as a Standard Household Application........... 17
1.6.4 AM Advancing Medical Technology and Helping Lives.................... 18
1.6.5 AM of Bi-Metallic and Multi-Material Structures.............................. 19
1.7 Summary......................................................................................................... 19
Problems...................................................................................................................20
References.................................................................................................................20
1
2 Additive Manufacturing
1.1 INTRODUCTION
Additive manufacturing (AM) is a technology that is rapidly developing and is being
integrated into manufacturing and also our day-to-day lives. Its emergence into the
commercial world has been labeled by a variety of names, such as three-dimensional
(3D) printing, rapid prototyping (RP), layered manufacturing (LM), or solid free-
form fabrication (SFF). Conceptually, AM is an approach where 3D designs can be
built directly from a computer-aided design (CAD) file without any part-specific tools
or dies. In this freeform layer-wise fabrication, multiple layers are built in the X-Y
direction on top of one another to generate the Z or 3rd dimension. Once the part is
built, it can be used for touch and feel concept models, tested for functional prototypes,
or used in practice. The everyday consumer should realize that AM can be a way to
connect with manufacturers on a new level. AM is much more than a process that can
be used to make personalized novel items or prototypes. With new developments in
AM, we live in an age that is on the cusp of industrialized rapid manufacturing tak-
ing over as a process to mass produce products and make it economically feasible to
design and create new ones in a timely fashion. As a result, the manufacturing process
of sectors across the globe will adapt to these developments while incorporating a new
style of customer–manufacturer interaction. AM allows people to contribute to the
design process from almost any location at all and will break the barriers of localized
engineering and emerge on a global scale. Just as the Internet has given us the ability
to spread and access information from any location at all, digital designing and CAD
have given people the ability to make, change, and critique designs from anywhere.
With AM, those designs can be made and tested from almost any location at all with
very little lead time. The capabilities of AM machines have become sophisticated to
a point where thinking of the design and drafting the model in CAD is the limitation
instead of the manufacturability of the product.1 As a new generation grows up with
CAD technology and the abilities and availability of AM machines grow, the process
of designing a product will mature from being created by a select group of engineers
to being created by the consumer and company together, with the final product being
able to be manufactured anywhere in the world in a timely manner.
1.2 HISTORY OF AM
1.2.1 Start of 3D Printing
AM was first developed in the 1980s when a man named Charles “Chuck” Hull invented
the first form of 3D printing called stereolithography (SLA). It was the advancements
in laser technology, along with Mr. Hull’s innovation on the materials and process that
he used, that first made this conceptual method a reality.2 Stereolithography is a sys-
tem where an ultra-violet (UV) light source is focused down into an UV photo-curable
liquid polymer bath, where, upon contact, the polymer hardens. Patterns can be drawn
using the ultra-violet source to semi-cure the polymer layer. Uncured polymer stays in
the bath and provides support to the part that is being built. After a layer of printing is
done, the hardened polymer layer moves down on a build plate in the liquid medium,
and the next layer of polymer is available on top for the following layer. This process
Introduction to Additive Manufacturing 3
continues until the part is finished based on the CAD design and is removed from the
liquid medium. In most cases, further curing is needed before the part can be touched.
It was in 1983 when Chuck Hull invented this new technology, and, subsequently,
in 1986, he formed the very first company to develop and manufacture 3D printers
called 3D Systems.2 This was the first step in the history of making an RP machine
outside of science fiction movies or books. Mr. Hull was also the first to devise a way
to allow CAD files to communicate with the RP system in order to build computer
modeled parts. Such an endeavor was not trivial. To accomplish this, 3D CAD models
had to be sliced in a virtual world, and then each slice could be used to build a layer
using the 3D printer. In the first-generation CAD files for 3D printers, only the surface
files mattered, which were termed. stl files from the stereolithography process. After
developing this technology, the patent application was filed in August 1984 and was
approved in 1986 by the United States Patent and Trademark Office (USPTO), mak-
ing it the first patent of an RP system.3 Though Chuck Hull patented this technology
in 1986, it took several years for 3D Systems to launch the first solid state stereolithog-
raphy system.2
Solidscape®, released its first 3D printer called the ModelMaker™ 6 Pro in 1994.9
This machine used an inkjet approach to build a part.10 This method essentially
acts the same as stereolithography, but instead of a laser being focused into a liquid
medium, hot thermoplastic wax liquid is sprayed onto a plate to build each layer
of a part. This machine could make high resolution wax models which were very
popular for businesses that perform complex investment casting such as the jewelry
industry.11 The company experienced commercial success and was later bought
by Stratasys, Inc. in May of 2011.12
The above mentioned are just some of the original RP systems that were being
developed at that time, yet these founders were not the only people who saw the signifi-
cance of these technologies. Once 3D Systems patented stereolithography, companies
in other countries started to develop this technology as well. In Japan, two compa-
nies called NTT Data CMET and Sony/D-MEC started to develop stereolithography
systems in 1988 and 1989, respectively.13 In addition, companies in Europe such as
Electro Optical Systems (EOS) and Quadrax developed stereolithography systems in
1990.13 Many companies around the globe were starting to develop their own 3D print-
ing devices and coming up with unique ways to improve the process. It was apparent
3D printing had sparked worldwide interest at its inception, and since the early 1990s,
rapid development of the process has been present across the globe.
1.2.3 Moving from RP to AM
At this point, most of the technologies were developed to produce polymeric
objects and had not been able to process other materials such as metals or ceram-
ics. Inherently, these machines were limited to the prototyping stage and not at the
full-on manufacturing stage where the finished parts are made to be used. It took
further development in RP technology in order to produce parts out of metals and
ceramics. In order to push the boundaries of RP and bring the technology to a manu-
facturing level, several companies were trying to develop a metal AM machine. One
of the first was a company mentioned before called EOS, which was started in 1989
by Dr. Hans J. Langer and Dr. Hans Steinbichler.14 They began working on printing
plastic parts using stereolithography systems and then SLS. In the early 1990s, they
started to research using SLS to make metal parts and presented their first proto-
type of a direct metal laser sintering (DMLS) machine in 1994. Subsequently, they
launched the first DMLS system in 1995.14 This process worked similarly to SLS,
but could sinter metal powders. Initially, the metals that could be used in this process
were many general engineering materials such as aluminum, cobalt, nickel, stainless
steel, and titanium alloys.14 In 1997, EOS sold its stereolithography product line to
3D Systems and took over the global patent rights for laser sintering technology.14
Since then, it has significantly advanced SLS and DMLS and has made it one of the
most popular AM processes in manufacturing. As a result, this has made EOS one
of the most successful and competitive AM companies in the world.
Around this same time, another AM technology that could produce metal parts
called laser engineered net shaping (LENS®) was being developed in Albuquerque,
New Mexico. It was developed by Sandia National Laboratories in 1997 and was
eventually commercialized by Optomec.15 The first machine was sold in 1998.16,17
Introduction to Additive Manufacturing 5
The LENS® system worked by depositing powder under a high-power laser where
it was melted and solidified on a substrate. The base and head were both mobile which
made it so the metal could be deposited in selected areas of the substrate. The metal
was then deposited layer by layer until the desired part was built.18 Optomec has
continued to advance LENS® technology and is constantly updating its product line
to fit the ever-changing consumer interests.
Another popular type of AM process also being developed in the late 1990s was
electron beam melting (EBM). A company called Arcam AB started in 1997 creat-
ing EBM technology.19 EBM worked by shooting an electron beam at a powder bed
in selective areas. Once a layer of powder had been melted in selected areas, another
layer of powder was laid on top of the previous one, and the process was continued
until the part was complete.20 Working with Chalmers University of Technology,
Arcam AB released its first EBM machines and sold them to two clients in 2002.19
In 2007, a manufacturer of orthopedic implants made a Fixa Ti-Por hip implant that
was Conformité Européenne (CE)-certified using EBM technology.19 Since then,
more implants have been made using EBM. EBM is also being used in the aerospace
industry, and as it continues to develop, so do the number of applications that are
found that benefit from its use.
1.2.4 Impact of AM
Since the emergence of these technologies and companies, the AM industry has
constantly been expanding, growing, and advancing with much enthusiasm. With
many industries seeing the lucrative value and abilities of AM, the global market has
been expanding very quickly, as shown in Figure 1.1. Many new types of RP and AM
methods have been created since these original pioneers first started developing the
technology. Some new technology has been novel and some were just variations of
the established methods. There has also been a lot of development in the materials
that can be used, as well as research into making their properties optimal for end use.
These original technologies all started as RP, layered manufacturing, or solid free-
form fabrication methods, where they were designed to only make quick prototypes
or “show and tell parts” using polymeric materials. Over the years it has moved
into AM, where functional prototypes and parts can be made to perform in a vari-
ety of environments. As AM has been incorporated into industry, its global market
has steadily increased since the first 3D printer was made. Due to this continuous
exponential growth in interest and adoption of the technology, it has been predicted
that >10% of products and components produced will be influenced by AM.21 AM
will continue to become more integrated into industry and our personal lives as the
technology and availability continue to grow.
Design Intellectual
Materials
Manufacturing Product
Processes
Much more goes into manufacturing in addition to these four subcategories, such
as intellectual property and demand. Through conventional manufacturing, avail-
ability of a skilled workforce and manufacturing facilities are factors for creating a
product in high demand. For example, processes like forging, pressing, and extrusion
require heavy machinery, large floor space, and a skilled workforce in order to ensure
efficiency during and between manufacturing steps. Then, with demand determin-
ing part volume requirements, efficiency is crucial to reduce lengthy lead times for
large volumes of parts. With a limited production volume, lead times can remain
long for high volume production. On the other hand, small volume production is
economically inefficient due to the long lead time, as well as a high tooling cost/part
ratio. With AM, however, lead times can be reduced, as the entire part is printed in a
single machine with no tooling requirements, which eliminates the need for multiple
machines in order to create the final product. This can be viewed in Figure 1.3, where
AM can reduce the time it takes to go from the first generation design to the final
design in the part manufacturing flowchart compared to conventional processes,
which require more intensive manufacturing steps. Also, with the only tooling cost
being the AM machine itself, and no specialized training required, the cost per part
remains relatively constant over any production volume range. The shorter lead time
to produce 3D concept models and less machine requirements are some of the key
advantages over conventional manufacturing and were the driving forces for the first
generation of additive manufacturing technologies.
Testing for
Low volume
Final design functional
production
properties
Another issue that large-scale production often leads to is a product that suits most
people’s needs, but does not cater to the individual consumer’s taste. Parts are
designed by engineers to fix an issue or fulfill a need of a consumer. Yet, for many
things, the general item that is made does not fit the exact needs of the individual
buyer because it is built for the general population instead. Likewise, the designers
that create the part are sometimes not experiencing the issue firsthand. They only
make the product to fit the specifications they receive however they receive them.
This trail of information is not always reliable or effective to make an optimal
product. Also, on a mass-scale production line, it can be hard if not impossible to
make custom products based on the tooling and methods that have been established.
This can limit the ability of manufacturers to make custom products.25 Therefore,
the large-scale production of many goods does not accommodate the individual likes
and tastes of consumers. As a consequence, this way of manufacturing results in the
consumer settling for something that is just adequate. Though this is OK for many
circumstances, if we have the resources to make things exactly how we want them,
then why wouldn’t we?
Let’s take a scenario where someone wants a desk and desires certain shelves,
drawers, and size of the desk to fit their office. Possibly, they want some custom
designs built into the desk to make it personal. A manufacturer has built a series
of desks with a certain configuration of storage space and has made it so the desk
can fit through a standard door. Yet maybe none of the available desks are designed
exactly as this particular person wishes. The person could try and contact the
manufacturer and see if they could custom build a desk for him. Since this would
disrupt the production line, it would likely cost a substantial amount more, if it
Introduction to Additive Manufacturing 9
could even be done at all. Also, there usually tends to be an issue with communi-
cation from two different locations, and describing exactly what the person wants
could be difficult. In the end, this person will most likely buy the desk that fits their
needs the closest and will settle for something that is not quite exactly what they
wanted. Now back to the question from before, what if making a perfect desk is
possible, could be done easily, and was cost effective; do you think the consumer
would spend a little more money and effort to buy that? Of course, they would,
and with the current state and development of AM, as well as the availability and
improvement of CAD, this could soon be a reality across a variety of consumer
products.
no restriction besides the size of the part, which has to fit in the machine. Now,
the designer only has to design their part so that it can fit the specifications for
its own application instead of largely considering manufacturing restrictions into
their design. Another benefit to this process is the only tooling involved is a single
AM machine, so a constant tooling cost is eliminated. Though some parts must
be machined afterwards to have the right surface finish, there is much less tooling
required as compared to conventional methods. This reduced tooling eliminates a
huge cost of production. The only other cost is maintenance of the machine. AM also
saves material because it is an additive technique as opposed to reduction technique.
An example of a reduction manufacturing method is milling, where the product
starts as a block with dimensions larger than the final product. The excess material
is then removed until the final dimensions are achieved. The waste material is then
either disposed of or recycled, for which the manufacturer usually has to pay. With
AM, material is added until the product is made so little to no material is lost, which
can equate to a 75% reduction in material use and can lower the production time and
cost by 50%.26 These huge savings are one of the reasons that AM has sparked so
much interest with manufacturers.
Figure 1.4 demonstrates how the cost per part generally changes for part volume
and complexity through additive manufacturing and conventional manufacturing
processing. At low part volume and high complexity, the cost per part is the high-
est. In contrast, AM processes are generally a horizontal line in both graphs, which
begins to show the regimes where AM can outperform conventional processing.
It should also be noted that with the technological revolutions in the AM commu-
nity, as well as the widespread adoption of additive technology throughout multiple
industries, the AM cost per part vs. part volume trend is decreasing over time. In the
future, this trend will likely continually decrease with increased implementation of
the technology.
FIGURE 1.4 Comparison of cost per part vs. part volume and complexity for conventional
manufacturing and additive manufacturing.
Introduction to Additive Manufacturing 11
In many traditional manufacturing methods this can be very difficult. For example,
in a casting process, once an expensive die is made, it cannot be changed that day to
accommodate an alteration in the design. This is why AM started as a process that
could be used to make a new part fast and cheap to test to see if it would work for
the application. AM still has this capability, which is an undoubtedly powerful tool,
but now has moved into being able to produce ready-to-use parts. It also makes it so
on-demand building is much easier and costs less. If a designer wants to try some-
thing new, or a customer wants a custom part, it can be built easily without disrupting
normal production.
Additive
manufacturing
Advantages Challenges
Design freedom: AM can essentially make Surface finish: Post processing is needed
any geometry with no restrictions for optimal surface finish
No tooling: AM can make parts from start Slower build rates: High volume
to finish with no other tooling required production is limited
Saves material: Due to near net shape High printer cost: Large capital
processing, it creates less waste than investment is needed for high end printers
machining
FIGURE 1.6 Visuals of parts with different features that are simply manufacturable with
AM. (From Roschli, A. et al., Addit. Manuf., 25, 275–285, 2019.)
14 Additive Manufacturing
Language: Finnish
Historiallinen romaani
Kirj.
STANLEY J. WEYMAN
V. Hämeen-Anttila
SISÄLLYS:
I. Fécampin markkinat.
II. Solomon Notredame.
III. Mies ja vaimo.
IV. Kaksiovinen talo.
V. Ylempi holviovi.
Vi. Kiinnytysjauhe.
Vii. Klytemnestra.
VIII. Kainin merkki.
IX. Oikeuden edessä.
X. Kaksi todistajaa.
I.
Fécampin markkinat.
"En."
"Minä."