ADDITIVE MANUFACTURING

Sozharajan Balasubramani
BITS Pilani 2022PHXP0009U
Dubai Campus Supervisor; Dr.R.Karthikeyan

11/24/2022
SOZHARAJAN B
 CONTENTS

1.Introduction
2. History of Rapid Prototyping
3. Rapid Prototyping Technologies
 Stereolithography (SLA)
 Fused Deposition Modeling (FDM)
 Laminated Object Manufacturing (LOM)
 Selective Laser Sintering (SLS)
 Laser Engineered Net Shaping (LENS)
 Electron Beam Melting (EBM)
 Three Dimensional Printing (3DP)

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 Two Ways for Fabrication

Subtractive manufacturing Additive Manufacturing

Some other names:

 Additive manufacturing
 Computer controlled mold less additive manufacturing
 Layered manufacturing
 Rapid prototyping:
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 Definition
Rapid prototyping is basically a additive manufacturing process used to quickly
fabricate a model of a part using 3-D CAM data. It can also be defined as layer
by layer fabrication of 3D physical models directly from CAD.

Basic Principles of Rapid Prototyping

 3d model generated
 Sliced
 Each slice manufactured and layers are fused together

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 STL File

 The STL (stereo lithography) file format is widely used for rapid prototyping and
computer-aided manufacturing (CAM).
 STL files describe only the surface geometry of a three dimensional object without any
representation of color, texture or other common CAD model attributes.
 It is a raw unstructured triangulated surface by the unit normal and vertices (ordered by
the right-hand rule) of the triangles using a three-dimensional Cartesian coordinate
system.

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 Methodology of Rapid Prototyping

Pre Processing
 Construct a CAD model.
 Convert it to STL format.
Processing
 RP machine processes .STL file by creating sliced layers of model.
 First layer of model is created.
 Model is then lowered by thickness of next layer.
 Process is repeated until completion of model
Post Processing
 The model & any supports are removed.
 Cleaning with alcohol and Curing.

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 Conventional Machining vs Rapid Prototyping

Conventional Machining Need for Rapid Prototyping

 Its not suitable for complex shapes  To increase effective communication.

because they are difficult to
machine.
 Time consuming
 Very costly
 Tedious or very laborious.
 Skilled operator is required.
 Accuracy will be less.
 Increased product development time.
 To decrease development time.
 To decrease costly mistakes.
 To minimize sustaining engineering
changes.
 To extend product life time by adding
necessary features & eliminating redundant
features early in the design.

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 Examples of Rapid Prototyping Applications

Prototyping (90 %) Manufacturing (10%)

 Concept models  Implants and custom medical
 Architectural models devices
 Aerospace parts

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 History of Rapid Prototyping

 It started in 1980’s
 First technique is Stereolithography (SLA). It was developed by 3D systems of
Valencia in California, USA in 1986.
 Fused deposition modelling (FDM) developed by stratasys company in 1988.
 Laminated object manufacturing (LOM) developed by Helisis (USA).
 Solid ground Curing developed by Cubitol corporation of Israel.
 Selective laser sintering developed by DTM of Austin, Texas (USA) in 1989.
 Multi Jet Modelling by 3D systems.
 3-D Printing by Solygen incorporation, MIT, USA.

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 Rapid Prototyping Technologies

 Stereolithography (SLA)
 Fused Deposition Modeling (FDM)
 Laminated Object Manufacturing (LOM)
 Selective Laser Sintering (SLS)
 Laser Engineered Net Shaping (LENS)
 Electron Beam Melting (EBM)
 Three Dimensional Printing (3DP)

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 Materials For Rapid Prototyping
Materials covered:
 Thermoplastics (FDM, SLS)
 Thermosets (SLA)
 Powder based composites (3D printing)
 Metals (EBM, SLS,LENS)
 Sealant tapes (LOM)
Selection of Optimal Process
Functional parts: Non functional parts:
FDM (ABS and nylon) SLA: smoothest surface, good for
SLS (thermoplastics, metals) casting.
EBM (high strength alloys, Ti, LOM, 3D Printing, marketing and
stainless steel, CoCr) concept prototypes.
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 STEREOLITHOGRAPHY (SLA)

 SLA is a laser based Rapid Prototyping process which builds parts directly from CAD by
curing or hardening a photosensitive resin with a relatively low power laser.
 Build Materials Used; Thermoset polymers, photosensitive resins
{ Epoxy Resin, Acrylate Resin }

Parameters:
 Laser Type: Helium Cadmium Laser (He-Cd)
 Laser Power: 24mW
 Laser Life: 2000 hours
 Minimum Slice Thickness: 0.1mm
 Beam Diameter: 0.2mm
 Scan Speed: 0.75m/sec
 Maximum Part Volume: 0.25x0.25x0.25 m
 Maximum Part Weight: 9 kgs

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Post Processing:

 Clean the part in the alcohol bath and then go for final curing in oven.
Advantages: Disadvantage:
 Parts have best surface quality.  It requires Post Processing. i.e. Post
 High Accuracy & High Speed. Curing.
 No need for support material  High cost of Photo Curable Resin.
 Thin vertical walls, sharp corners & tall
columns can be fabricated with ease
Applications:
 Patterns for metal processing (Ex. Investment
Casting , Wind Tunnel Molding & Injection
Mold Tools).
 Prototypes for demonstrational purposes .
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 FUSED DEPOSITION MODELLING (FDM)

 Fused Deposition Modeling is an extrusion based rapid prototyping process although it works
on the same layer by layer principle as other RP systems.
 Fused Deposition Modeling relies on standard STL data file for input and is capable of using
multiple build materials in a build or support relationship.
Build Materials; Investment Casting Wax, ABS Plastic, PLA, Elastomer.

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Advantages:
Disadvantage:
 Strength and temperature capability of build
 Process is slower than laser based
materials.
systems.
 Safe laser free operation and Economical
 Build Speed is low.
(inexpensive materials)  Thin vertical column prove difficult to
 Easy Post Processing.
build with FDM
Applications:
 Concept or Design Visualization.
 Investment Casting Patterns.
 Medical Applications
 Flexible Components

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LAMINATED OBJECT MANUFACTURING (LOM)
 LOM is actually more of a hybrid between subtractive and additive processes, in that the
models are built up with layers of material, which are cut individually by a laser in the shape
of the cross section of the part. LOM is one of the fastest RP processes for parts with larger
cross-sectional areas, which makes it ideal for producing larger parts.

 Materials Used; paper, plastic sheets, composites

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Advantages:
Disadvantage:
 Wide variety of materials.
 Precise power adjustment
 Fast build time
 Difficult to Fabrication of thin walls
 High precision
 Removal of the scrap material is difficult
 There is no need for additional support Material

Applications:
 Pattern Making
 Decorative Objects

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 SELECTIVE LASER SINTERING

 The build media for Selective Laser Sintering comes in powder form which is fused together
by a powerful carbon dioxide laser to form the final product.
 Materials Used; Powdered plastics (nylon, polyamide, polycarbonate and Thermoplastic
Elastomer), metals (steel, titanium, tungsten), ceramics (silicon carbide)

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 Advantages:
 Good part stability Disadvantages:
 Support structures not required.  High power consumption
 High precision  Cost of the System (Initial and Maintenance)
 No post-curing required.  Large physical size of the unit
 Large parts can be built.  The quality of metal parts is not as high as
with EBM
Applications:
 Concept models
 Functional models and working prototypes
 Polycarbonate (Rapid Casting) patterns.
 Metal tools (Rapid Tool).

Reebok uses SLS Process for

Developing Sports Shoes
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 LASER ENGINEERED NET SHAPING (LENS)

 The LENS process builds components in an additive manner from powdered metals
using a Nd:YAG (neodymium-doped yttrium aluminum garnet) laser to fuse powder
to a solid. It is a freeform metal fabrication process in which a fully dense metal
component is formed.
 A deposition head supplies metal powder to the focus of a high powered Nd:YAG laser
beam to be melted. This laser is typically directed by fiber optics or precision angled
mirrors. When a layer is completed, the deposition head moves up and continues with the
next layer. The process is repeated layer by layer until the part is completed
 The fabrication process takes place in a low-pressure argon chamber for oxygen-free
operation in the melting zone, ensuring that good adhesion is accomplished.

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 Materials Used; stainless steel alloys (316, 304L, 309, 17-4), nickel-based super alloys
(tool steel alloys (H13), titanium alloy (6Al- 4V), and other specialty materials.

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 Optomec Lens Process

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 Advantages: Disadvantages:
 Superior material properties  Limited materials (Only for Metals).

 Production of Complex parts.  Large physical unit size

 Reduced post-processing requirements  Large power consumption

 Surface finish is required
Applications:
 Build mold and die inserts.
 Producing titanium parts in racing industry
 Fabricate titanium components for biological implants
 Produce functionally gradient structures
 This technique can be used with a wide variety of metals
including titanium, tool steels, stainless steels, copper and
aluminum.
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H13 Tooling WES Housing

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 Impeller Fixtures

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 Electron Beam Melting (EBM)
 EBM is a powder-based method having a lot in common with SLS, but replaces the laser
with a scanned 4 kW electron beam to produce fully dense parts, although porosity cannot
easily be avoided due to the nature of the laser sintering process.
 Materials Used; Titanium, Tungsten, Stainless steel, Cobalt-Chrome, Ni-based super
alloys.

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 Advantages:
Disadvantages:
 Wide range of metals and high quality metal parts
 Extremely expensive (more
 Fully dense parts with very homogeneous microstructures
than SLS)
 High temperature operation (700-1000 C) results in
0
 Conventional machining may
structures free of internal stresses
be required to finish the goods
 EBM allows even better microstructural control than
(rough surface)
many conventional processes
 Requires vacuum operation
Applications:
 Structural components for aerospace (Ti-6Al-4V, Ni super alloys)
 Custom-made bio-implants (Ti-6Al-4V)

HIP Joint Metal Part Made By EBM

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 THREE DIMENSIONAL PRINTING (3DP)

 The 3D printing process begins with the powder supply being raised by a piston and a leveling roller distributing a
thin layer of powder to the top of the build chamber. A multi-channel ink-jet print head then deposits a liquid adhesive
to targeted regions of the powder bed. These regions of powder are bonded together by the adhesive and form one
layer of the part. . The remaining free standing powder supports the part during the build.

 Material Used; Plaster, sand, oxide ceramics, sugar and starch for food printing

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 Advantages: Disadvantages:
 High Speed  Limited Functional Parts
 Versatile.  Limited Materials
 Simple to operate  Poor Surface Finish
 No wastage of materials.

Applications:
 Widely used to print colorful and
complex parts for sports and Medical
industries
 Molds for sand casting of metals

3D printed Jaw Used in Guitar

Medical Transplant

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 BIO PRINTING

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Advantages
 The waiting list for transplant can be reduced considerably.
 Offers high precise resolution scan can be obtain and software can calculate the exact size
of the desired replacement.(eg bones)
 Quick process ,10 days to print an average sized liver and lobe. Time will be reduced
considerable as the technology advances.
 Artificial organ personalized using patients own cells
 No DNA rejection

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Disadvantages

 It will bring a major ethical and moral debate on its use .

 Implanted organ can be rejected as body cant accept them as functional tissue.

 The cost of printers are very expensive.

 Possibly more expensive than regular organ transplant

 Cost of using stem cells

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REFERENCES
1.Chua, C.K., Leong K.F. and Lim C.S., “Rapid prototyping: Principles and applications”,
second edition, World Scientific Publishers, 2010.
2. Gebhardt, A., “Rapid prototyping”, Hanser Gardener Publications, 2003.
3. Gibson, I., Rosen, D.W. and Stucker, B., “Additive Manufacturing Methodologies: Rapid
Prototyping to Direct Digital Manufacturing”, Springer, 2010.
4. Hilton, P.D. and Jacobs, P.F., Rapid Tooling: Technologies and Industrial Applications, CRC
press, 2005.
5. Kamrani, A.K. and Nasr, E.A., “Rapid Prototyping: Theory and practice”, Springer, 2006. 6.
Liou, L.W. and Liou, F.W., “Rapid Prototyping and Engineering applications : A tool box for
prototype development”, CRC Press, 2011.

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 THANK YOU

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