Advanced CAD for Additive

Manufacturing
ADJ. PROFESSOR - GARY MAC
01/26/2017
About Me

 Graduated NYU Tandon in Spring 2016 – BS/MS in M.E.

 Employed at TriMech (previously CADD Edge) since Fall 2014
 Reseller of SolidWorks products and 3D printers
 Certified SolidWorks Expert
 Provide technical support to customers
 Instructor for basic/advanced CAD courses
About Me
Syllabus

 ME-GY 7863 Special Topics (Advanced CAD for Manufacturing)

 Email: gm1247@nyu.edu
 Grading Policy:
 Midterm 1: 30 %
 Midterm 2: 30 %
 Project: 40 %
Intro to Additive Manufacturing

 ISO/ASTM52900-15 (Standard Terminology for AM)

 “Process of joining materials to make parts from 3D model data, usually layer upon layer, as
opposed to subtractive manufacturing and formative manufacturing methodologies”
 3D printing
 “Fabrication of objects through the deposition of a material using a print head, nozzle, or
another printer technology”
Intro to Additive Manufacturing
Classification of AM Technology
Material Extrusion

 Fused deposition modeling (FDM)

 Heating a thermoplastic polymer filament in an extruder and depositing a 2D layer on a
platform
 Additional 2D layers are built on top of the previous layer
 Each layer cools and bonds to the previous layer as it hardens
 Hollow areas of the model are built with a support material that can be washed away
 Filament – ABS(acrylonitrile butadiene styrene), PLA(polylactic acid)
Material Extrusion
Powder Bed

 Selective laser sintering (SLS)

 Use of a laser to heat a bed of uniform powder to fuse them together
 Selectively curing the material in the shape of the model to form each layer
 Process of laying a bed of powder and fusing it into the part repeats until the part is complete
 Materials can include thermoplastic polymers, glass, ceramics, and metal alloys
 Typical metallic powders include stainless steel, cobalt chrome, aluminum, and titanium
Powder Bed
Photopolymerization

 Stereolithography (SLA)
 Use of a UV lamp/laser to cure a photosensitive polymer into a solid
 Focus UV light onto the surface of a tank filled with liquid photopolymer to solidify and form
the layer of the model
 Path is define by the slices of the model
 Print bed is lowered into the tank and the process is repeated for a new layer
 Object then rinse with solvent to remove uncured photopolymer and placed into an UV oven to
complete curing process
Photopolymerization
Case Study - Normal
Case Study – American Standard
Case Study – GE Aviation

 3D printed fuel nozzle for jet engine

 Made by direct metal laser sintering
 Cobalt-chromium alloys
 Prints in one piece
 Previously had to be assembled from 20
different parts
Advantages of AM

 Elimination of tools such as molds and dies needed in traditional manufacturing process
 AM allows for the fabrication of pre-assembled parts
 Complex geometry that might be impossible to create with traditional manufacturing
technique
Intro to CAD

 SolidWorks
 What do we already know?