Additive Manufacturing

Part 1
 What is Additive Manufacturing?

• Additive Manufacturing used to be referred to as Rapid

Prototyping (RP).
– Rapid prototyping is used to describe a process for rapidly
creating a system or part representation before final release or
commercialization.
– In the context of product development, RP was used to
describe technologies which created physical prototypes
directly from digital model data.
 What is Additive Manufacturing?

• Modern advances now make it possible for these

technologies to produce objects that are close to or
identical to the final product.
– In a consensus by ASTM International, the associated
process are now referred to as Additive Manufacturing
(AM) to include all applications of the technology.
– AM is more popularly referred to as 3D Printing.
 What is Additive Manufacturing?

• AM processes make
parts by adding
material in layers.
– Each layer is a thin
cross-section of the part
derived from a three-
dimensional Computer-
Aided Design (3D CAD).
 What is Additive Manufacturing?
• The thinner the layers,
the closer the part will
be to the original
model.
• All current
commercialized AM
technologies use this

layer-based approach.
 How do AM Technologies Differ?
• AM machines primarily differ by:
– the materials used

– how the layers are created

– how the layers are bonded to each other.

• These differences affect:

– part accuracy

– physical and mechanical properties

– write speed

– post-processing

– AM machine size
– AM machine cost
The Generic AM Process
 The Generic AM Process
• Step 1: Computer-aided Design (CAD)
– All AM parts start from a software model that
fully describes the external geometry.
• Most professional CAD solid modeling software can be
used: Solidworks, Autocad, etc.
• Reversing engineering equipment can also be use:
laser and optical scanning, etc.
 The Generic AM Process
• Step 2: Conversion to STL
– STL, or Stereolithography File, is the standard file type
that nearly every AM machine accepts.
– Nearly every CAD system can output this format.
– The file describes the external closed surfaces of the
original CAD model and forms the basis for calculation
of the slices.
 The Generic AM Process
• Step 3: Transfer to AM Machine and STL File
Manipulation
– The STL file is transferred to the AM machine.
– Some general manipulation may be required:
• size
• position
• orientation for building
 The Generic AM Process
• Step 4: Machine Setup
– AM machine must be properly set up.
• materials

• energy source

• layer thickness

• timings

• etc.
 The Generic AM Process
• Step 5: Build
– Building the part is an automated process.
– Monitoring may be required to:
• ensure no errors

• replace materials

• remedy power or software glitches

• etc.
 The Generic AM Process

• Step 6: Removal
– Once the build has completed, the part(s) can be
removed.
– The complexity depends on the specific process.
– Interaction of the machine may be required to
ensure proper removal temperatures, etc.
 The Generic AM Process

• Step 7: Post-processing
– After removal, parts may require additional
cleanup before end-point use.
– Parts may need to be strengthened.
– Support features may need to be removed.
 The Generic AM Process
• Step 8: Application
– Parts may now be ready to use.
– Additional treatment may be required in some cases:
• Priming.
• Painting.
• Modifications to surface finish.
• Assembly with other mechanical or electronic components.
 Benefits of Additive Manufacturing
• AM is considered as one of a series of
disruptive technologies.
– The technology has the potential to change the
way we design products and setup new
businesses.
– We may be at the beginnings of a new industrial
revolution and manufacturing, as we know it, may
not exist in the future.
 What’s so Special About AM?
• Speed across many aspect is the key.
– Seamless transfer of 3D CAD to AM.
• Less concern over data conversion.
• Less concern over interpretation of design intent.

– Reduction in process steps.

• Often a single step process.

– Design changes are easily implemented.

– Timelines are easily predicted.
 Benefits of Additive Manufacturing
• Other manufacturing processes require:
– careful and detailed analysis of the part geometry
– order in which different features can be fabricated
– what tools and processes must be used
– what additional fixtures may be required.

• AM requires:
– basic dimensional details
– comparatively small amount of understanding of AM machines
– understanding of the materials used.
 AM versus CNC Machining

Fused Deposition Modeling CNC Milling

• Computer Numerical Controlled (CNC) machining technology

shares some aspects with Additive Manufacturing.
– Both are a computer-based technologies used for manufacture.
– They differ fundamentally in that CNC machining is a subtractive technique
and AM is an additive technique.
 AM versus CNC Machining

• Material Differences
– AM Technology
• Polymeric materials, waxes, paper laminates
• Composites, metals, ceramics

– CNC Machining
• Steels, metal alloys
• Medium-density fiberboard (MDF), machinable foams,
machinable waxes, some polymers
 AM versus CNC Machining
• Speed Differences
– High-speed CNC machining can
remove material much faster than AM
machines can add a similar volume of
material.
– AM can produce a part in a single
stage.
• Several parts may be batched together.

– CNC is generally a multistage process.

• Reposition and/or relocation.
• Use of more than one machine may be
required
 AM versus CNC Machining

• Complexity
– The higher the
complexity, the
greater the advantage
of AM over CNC.
• Some geometric
features may not be http://resources.parsons.edu/labs/3d-print-lab/
possible with CNC.
 AM versus CNC Machining
• Accuracy
– Typical AM resolution: a few
10s of microns.
• Depends on the deposition
technique and positioning
mechanism.

– CNC resolution depends on

positioning system and
http://www.bayengineering.co.uk
diameter of rotating cutting
tools.
 AM versus CNC Machining
– Geometry
• AM breaks up complex, 3D models in a series of simple 2D
cross-sections with a nominal thickness.
– Continuity is determined by how close the proximity of one cross-
section is with an adjacent one.

• CNC must form the object in 3D space.

– Freeform surfaces dramatically increase the need for changes in
workpiece orientation.
 AM versus CNC Machining

Features that represent problems using CNC machining.

Additive Manufacturing
Part 2
 Development of AM Technology
• Additive Manufacturing came about as a result of developments
in a variety of different technology sectors:
– Computers
• Improvement in computing power
• Improvements in data storage

– Computer-Aided Design (CAD)

– Other technologies
• Lasers • Materials
• Printing technologies • CNC Machining
• Programmable Logic
Controllers (PLCs)
 Classification of AM Processes
• AM can be
classified in
numerous
ways:
– Baseline
technology
– Raw material
– Two- 2D Classification used by Pham et Al.
dimensional • More exotic systems may not fit directly in
classification
this classification scheme.
 New AM Classification Schemes
• Seven process categories which use a common machine
architecture and similar materials transformation physics:
– Vat Photopolymerization
– Powder Bed Fusion
– Material Extrusion
– Material Jetting
– Binder Jetting
– Sheet Lamination
– Directed Energy Deposition
 Milestones in AM Development
• 1984
– Parallel patents were filed with similar concepts to create a 3D
object by adding material layer by layer:
• Japan: Murutani
• France: Andre et al.
• USA: Masters, Hull

– Charles Hull patent most influential that gave rise to 3D Systems.

• First company to commercialize AM technology with the
Stereolithography apparatus.
3D Systems First Stereolithography System

First AM technology from Charles Hull, founder of 3D Systems.

 Milestones in AM Development

• 1986
– Additional patents were filed, resulting in three additional
companies:
• Helisys (Laminated Object Manufacture or LOM)

• Cubital (Solid Ground Curing or SGC)

• DTM (Selective Laser Sintering or SLS)

– Helisys and Cubital no longer exist.

– DTM merged with 3D Systems in 2001.
 Milestones in AM Development
• 1989
– Scott Crump patented the Fused Deposition Modeling (FDM)
process.
• Formed the Stratasys Company

– A group from MIT patented the 3D Printing (3DP) process

• Licensed to technology to several companies, Zcorp was the most
successful.
– Zcorp was aquired by 3D Systems in 2012
 Milestones in AM Development
• 1994
– Sanders further developed ink-jet technology to
deposit droplets onto a substrate to form a 3D object

• 2001
– Objet Company is formed
• Uses ink-jet technology to print droplets of photocurable
resins.
• Merged with Stratasys in 2011.
 Vat Photopolymerization Processes
• Charles Hull created the first “3D printed” part in 1983 using the stereolithography
(SL) process. Also referred to as SLA, stereo lithography apparatus.

https://www.3dsystems.com
First Part created with AM Technology
• Liquid photopolymers are used as the build material.

• Support structures are required for some designs.

– Support structures must be created from the same material and removed in a post-
processing step.
 Vat Photopolymerization Processes

The stereolithography apparatus (SLA) (right) can build a part (left) in plastic, layer by layer, using a laser to
polymerize liquid photopolymer. (Source: Cutting Tool Engineering, December 1989.)

• A small, intense spot of light causes the liquid polymer to solidify

(or polymerize).
 Vat Photopolymerization Processes
• Advantages of Photopolymer Systems
– Thin layers

– Fine precision compared to other systems

• Disadvantages
– Poor material properties compared to other AM materials
• New resins have been developed that offer improved:
– Temperature resistance
– Strength
– Ductility

– Degradation can occur rapidly if UV coatings are not applied.

Vat Photopolymerization Processes

https://www.youtube.com/watch?v=8a2xNaA
kvLo
 Powder Bed Fusion Processes

• Powder Bed Fusion (PBD) processes were among the first

commercialized AM processes.
– Selective Laser Sintering (SLS) was the first commercialized PBF process,
developed at the University of Texas at Austin.

• All PBF processes include:

– One or more thermal sources for inducing fusion between powder particles

– A method for controlling powder fusion to a prescribed region of each layer

– Mechanisms for adding and smoothing powder layers.

 Powder Bed Fusion Processes

• Lasers are the most

common thermal
sources.

• Electron beams and

other thermal sources
are also used.
Schematic of a selective laser sintering (SLS) system
 Powder Bed Fusion Processes
• Advantages of Powder Bed Fusion processes
– The excess material acts as a natural support
– One of the broadest range of materials
• Plastics, waxes, metals ceramics, particulate
composites.

• Disadvantages
– Poor dimensional accuracy
– Poor surface roughness
Powder Bed Fusion Processes

https://www.youtube.com/watch?v=da5IsmZZ
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 Material Extrusion Processes

• Extrusion-based technology is currently the most popular

on the market.
– Machines are relatively inexpensive.
– Small footprints.

• Layers are formed using a principle similar to a hot glue

gun.
– Typically, thermoplastics are heated and extruded through a
nozzle.
 Material Extrusion Processes
• When a constant pressure is
applied, the semisolid
material flows a constant
rate producing a “road” with
a constant cross-section.

• The material must solidify

and bond to previously
deposited layers.
Schematic of a Extrusion-Based Systems
 Material Extrusion Processes
• Advantages of Material Extrusion processes
– Much simpler build cycle than other AM processes

– Equipment is compact and low cost

– Thermoplastic materials are generally nontoxic

• Disadvantages
– Limited selection of materials (material properties)
– Build time tends to be long compared to other processes
– Defects such as voids and visible hatch lines are typical
Material Extrusion Processes

https://www.youtube.com/watch?v=a_kbMUz
MKk0
 Material Jetting Processes

• Inkjet printing technology has been extensively

investigated since the 1960s.
– Historically based upon applications to the two-
dimensional printing industry.
– New application areas include:
• Electronics
• Optics
• Additive manufacturing
 Material Jetting Processes
• AM based on Material
Jetting (MJ) works by
dispensing the part
material from a print
head.
– In contrast to binder
jetting, where an
adhesive is printed onto
a powder bed.

Schematic of a Drop-on-Demand (DOD) Printing System

 Material Jetting Processes
• Advantages of Material Jetting processes
– Low cost
– High speed
– Ease of combining multiple materials (multiple colors)
– Scalability
• Adding additional print heads can increase print speed.

• Disadvantages
– Limited selection of materials
• Only waxes and photopolymers are currently commercially available.

• Part accuracy, for large parts in particular, is generally not as good as other
processes.
 Binder Jetting Processes

• Binder jetting methods were developed in the

early 1990s, primarily at MIT.
– They developed what they called 3D Printing (3DP).
• A binder is printed onto a powder bed to form part cross
sections.
• In contrast to powder bed fusion, where a heat source
melts the powders.
 Binder Jetting Processes
• In contrast to the Material
Jetting (MJ) processes,
Binder Jetting (BJ) only
delivers a small amount of
the part material from the
print head.
• Binder droplets form
spherical agglomerates of the
binder material and powder Schematic of the Binder Jetting Process
particles which also provide
bonding to the previous layer.
 Binder Jetting Processes
• Advantages of Binder Jetting processes
– Low cost
– High speed
– Scalability
• Adding additional print heads can increase print speed.

• Disadvantages
– Parts need to be left in the powder bed to set
– Post-processing required to remove/clean part
• Often an infiltrant is applied to add strength and other mechanical
properties.
 Sheet Lamination Processes

• One of the first commercialized (1991) AM techniques

was Laminated Object Manufacturing (LOM).
– Involved layer-by-layer lamination of paper material sheets cut
by a CO2 laser.

• Several other processes have been developed based on

this idea using other build materials and cutting
strategies.
 Sheet Lamination Processes
• Only the outer contours of
each layer is cut.
• Sheets can be either cut and
then stacked or stacked and
then cut.
• Several mechanisms have been
employed for layer bonding:
– Adhesive bonding
Schematic of the Laminated Object
– Thermal bonding Manufacturing (LOM) Process
– Clamping
– Ultrasonic welding
Directed Energy Deposition Processes

• Directed Energy Deposition (DED) processes

enable the creation of parts by melting material
as it is being deposited.
• A variety of materials can be used, but metal
powders are the most common.
– Often referred to as “metal deposition” technology.
 Directed Energy Deposition Processes
• DED processes direct
energy into a narrow,
focused region where melt
materials are being
deposited.
• Laser or electron beams
are the typical focused
heat source.
• Powders are most
common, but wire feed
Schematic of a Laser Powder Directed Energy
stock is also used. Deposition (DED) Process
https://www.youtube.com/watch?v=oL7bMhPTtDI