National Taiwan University of Science and Technology

~~High Speed 3D Printing Research Center~~

Development of Additive Manufacturing

 Development of AM
 AM developed along with the development of computer technology.

Advantages of computer technology to AM

Enables precise positioning and Control

Machine Control
of parts and equipment.

Enable easy manipulation of large CAD data while

Processing Power setting up the machine and when slicing the data
before building.

Makes the machine easier to

Good Graphics Capability
set up, operate, and maintain.

Allows easier and fast communication and

Networking Capability file transfer between computers and AM
machines.

Figure- General integration of an AM machine

 Computer-Aided Design Technology
 AM technology primarily make use of the output from Mechanical engineering and 3D Solid Mo
deling CAD software.
 CAD technology provides:
 Realism
 Complexity
 Speed in designing 3D models
 Accuracy
 Usability
 STL is now a standard output for nearly all solid modeling CAD systems prior to generating the slic
ed data.

STL uses triangles to describe the

surfaces to be built.

Figure-A CAD model on the left converted into STL format on the right
 Aside from computer technology, AM utilizes other technologies like…

Lasers

• Provide a high intensity and highly

collimated beam of energy that can be
moved very quickly

• Used for curing or heating.

Figure- Laser technology in VAT photopolymerization

(Source: http://canadamakes.ca/)
 Printing Technologies

• Possible to generate much higher pressures

so that it can be used to print photocurable
and molten resins as well as binders for
powder systems.

Figure-Printer technology used on an AM machine (photo courtesy of Stratasys)

 The Use of layers

• Almost every AM technology builds parts using

layers of material added together.

• The main reason is due to simplification of building

3D objects from layers of 2D cross-sections .

Figure - An architectural landscape model, illustrating the use of layers

(photo courtesy of LiD)
 Classification of AM Processes
 There are numerous ways to classify AM technologies.
 According to baseline technology
 Uses lasers,
 Uses printer technology,
 Uses extrusion technology, etc.

 According to the type of raw material input

 But these classifications are not good because some processes get lumped together in what seems
to be odd combinations.
 It is probably inappropriate, therefore, to use a single classification approach.
 Continued…..Classification of AM Processes

Figure-Layered manufacturing (LM) processes as classified by Pham (note that this diagram has
been amended to include some recent AM technologies)
 Continued…..Classification of AM Processes
Liquid Polymer Systems
 Liquid-based RP systems have the initial form of its material in liquid state.
 The liquid is converted into the solid state.
 The first commercial system was the 3D Systems Stereolithography process based on liquid photopolymers.

Discrete Particle Systems

 Discrete particles are normally powders that are graded into a uniform size and
shape and narrow distribution.
 The finer the particles the better, but there will be problems if the dimensions get
too small in terms of controlling the distribution and dispersion.
 The conventional 1D channel approach uses a laser to produce thermal energy in
a controlled manner to raise the temperature sufficiently to melt the powder.
 Polymer powders must therefore exhibit thermoplastic behavior so that they can
be melted and re-melted to permit bonding of one layer to another.
 The two main polymer-based systems commercially available are:
 Selective Laser Sintering (SLS) technology marketed by 3D Systems
 The EOSint processes developed by the German company EOS.
 Continued…..Classification of AM Processes

Molten material system

 Molten material systems are characterized by a pre-heating chamber that raises
the material temperature to melting point so that it can flow through a delivery
system.
 The most well-known method is the Fused Deposition Modeling system (FDM)
developed by the US company Stratasys.
 This approach uses an extrusion technique to deliver the material through a
nozzle in a controlled manner.
 Two extrusion heads are often used so that support structures can be fabricated
from a different material to facilitate part cleanup and removal.
 Continued…..Classification of AM Processes

Solid Sheet Systems

 One of the earliest AM technologies was the Laminated Object Manufacturing

(LOM) system from Helisys, USA.
 This technology used a laser to cut out profiles from sheet paper, supplied from a
continuous roll, which formed the layers of the final part.
 Layers were bonded together using a heat-activated resin that was coated on one
surface of the paper.
 Once all the layers were bonded together the result was very like a wooden block.

 A hatch pattern cut into the excess material allowed the user to separate away
waste material and reveal the part.
 New AM Classification Schemes
VAT Photopolymerization

Photopolymerization – Step by Step

1. The build platform is lowered from the top of the

resin vat downwards by the layer thickness.

2. A UV light cures the resin layer by layer. The platform

continues to move downwards and additional layers
are built on top of the previous.

3. Some machines use a blade which moves between

layers in order to provide a smooth resin base to
build the next layer on.

4. After completion, the vat is drained of resin and the

object removed.

Figure-Schematic diagram of the SLA Process

Source : www.lboro.ac.uk http://www.custompartnet.com/wu/steri
olithography
 Powder Bed Fusion

Powder Bed Fusion  – Step by Step

1. A layer, typically 0.1mm thick of material is

spread over the build platform.

2. A laser fuses the first layer or first cross

section of the model.

3. A new layer of powder is spread across the

previous layer using a roller.

4. Further layers or cross sections are fused

and added.

5. The process repeats until the entire model is

created. Loose, unfused powder is remains
in position but is removed during post
processing. Figure-Schematic diagram Selective laser Sintering (SLS)
http://www.custompartnet.com/wu/selective-
laser-sintering
Source : www.lboro.ac.uk
 Material Extrusion

Material Extrusion  – Step by Step

1. First layer is built as nozzle deposits material where

required onto the cross sectional area of first object
slice.

2. The following layers are added on top of previous

layers.

3. Layers are fused together upon deposition as the

material is in a melted state.

Figure-Schematic diagram of Fused Deposition Modelling

http://www.custompartnet.com/wu/fused-
deposition-modeling
Source : www.lboro.ac.uk
 Material Jetting

Material Jetting  – Step by Step

1. The print head is positioned above build platform.

2. Droplets of material are deposited from the print

head onto surface where required, using either
thermal or piezoelectric method.

3. Droplets of material solidify and make up the first

layer.

4. Further layers are built up as before on top of the

previous.

5. Layers are allowed to cool and harden or are cured

by UV light. Post processing includes removal of Figure-Schematic diagram of Material Jetting
support material.
http://www.custompartnet.com/wu/ink-
jet-printing
Source : www.lboro.ac.uk
 Binder Jetting

Binder Jetting  – Step by Step

1. Powder material is spread over the build platform

using a roller.

2. The print head deposits the binder adhesive on top

of the powder where required.

3. The build platform is lowered by the model’s layer

thickness.

4. Another layer of powder is spread over the previous

layer. The object is formed where the powder is
bound to the liquid.

5. Unbound powder remains in position surrounding

the object.

6. The process is repeated until the entire object has Figure-Schematic diagram of Binder Jetting Process
been made. http://www.custompartnet.com/wu/3
d-printing
Source : www.lboro.ac.uk
 Sheet Lamination

Sheet Lamination  – Step by Step

1. The material is positioned in place on the cutting

bed.

2. The material is bonded in place, over the previous

layer, using the adhesive.

3. The required shape is then cut from the layer, by

laser or knife.

4. The next layer is added.

5. Steps two and three can be reversed and

alternatively, the material can be cut before being
positioned and bonded. Figure-Schematic diagram of LOM Process
http://www.custompartnet.com/wu/laminated-
object-manufacturing
Source : www.lboro.ac.uk
 Direct Energy Deposition

Direct Energy Deposition – Step by Step

1. A4 or 5 axis arm with nozzle moves around a fixed

object.

2. Material is deposited from the nozzle onto existing

surfaces of the object.

3. Material is either provided in wire or powder form.

4. Material is melted using a laser, electron beam or

plasma arc upon deposition.

5. Further material is added layer by layer and

solidifies, creating or repairing new material features
on the existing object.
Figure-Schematic diagram of Direct Metal Deposition Process

https://www.researchgate.net/publication/335970676_Analytical_Modeling_a
Source : www.lboro.ac.uk nd_Experimental_Investigation_of_Product_Quality_and_Mechanical_Properti
es_in_FDM_Additive_Manufacturing/figures?lo=1
Hybrid Systems (Hybrid-AM)

• The additive element is dominant and that the

subtractive component is important but
relatively insignificant.

Source : https://journals.sagepub.com/doi/abs/10.1177/0954406219861664
Important Milestones of AM

Source : Deloitte. Challenges of Additive Manufacturing.pdf

Source : Deloitte. Challenges of Additive Manufacturing.pdf
Figure - The first AM technology from Hull, who founded 3D systems (photo courtesy of 3D
Systems)
 Future of Additive Manufacturing

 From Prototyping to serial

production.
 Introduction of Wide Range of
Materials.
 Introduction of High Speed
Additive Manufacturing.
 Production of highly accurate
parts.

Figure – Expected Market Value of AM in the

near future
Source : Deloitte. Challenges of Additive Manufacturing.pdf