ADDITIVE MANUFACTURING

WHAT IS ADDITIVE MANUFACTURING?

• Additive Manufacturing is a method in which the part is created by a layer- additive process.

• Using a specialized software, a 3-D CAD model is cut into very thin layers or cross-sections.

• Then, depending on the specific method used (sintering, fused deposition, etc.), the AM machine constructs the part layer by
layer until a solid replica of the CAD model is generated.

• The advantages of this process is clear: development of physical models can be accomplished in significantly less time as
compared to the machining process.
AM for Product Development Process

Concept System-Level Detail Testing & Production

Development Design Design Refinement Ramp-Up

Concept System-Level Detail Testing & Production

Development Design Design Refinement Ramp-Up
Input Material
Paper, Resins, Nylon, ABS,
• Physical Objects Wax, metals, ceramics
• CAD Models • Liquid
• STL Files • Powder
• Sliced Model Files • Solid

RP

Method Applications

• Design
• Photocuring •Engineering, Analysis&Planning
• Cutting&Gluing •Manufacturing&Tooling
• Melting&Solidifying
• Binding
• RP requires a closed
volume of the model
• What you see may
not be what you get

The tessellated model

 Basic Steps of AM Processes
Computed Tomography Create a CAD model of the design
Scan

Convert the CAD model to

STL format

Slice the STL file into layers

Construct the physical model

layer by layer

Clean and finish the model

 Advantages of AM
• Reduce product development time and cost.

• Get products to market sooner.

• Enhance communications between marketing, .engineering, manufacturing, and

purchasing.

• Present physical model at critical design reviews.

• Perform functional prototype testing before committing to tooling.

• Generate precise production tooling.

 Issues in Layered-Based Manufacturing

• Staircase effect
• Layer thickness
• Accuracy
• Part orientation
• Support Structures
 AM Processes

Material Basic Process Process Name

Gluing Sheets Laminated Object Manufacturing

(LOM)
Solid
Melting+Solidification Fused Deposition Manufacturing
(FDM)

Material powder Selective Laser Sintering

(SLS)
Powder
Material+Binder 3D Printing

Solid Ground Curing

Liquid
(SGC)
Liquid Polymerization
Stereolithography
(SLA)

Steen, Laser Material Processing

 Applications of AM
Design
• CAD model verification.
• Visualizing objects.
• Proof of concept.
• Market and presentation application.

Engineering Analysis and Planning

• Form and fit.
• Stress analysis.
• Mock-up parts.
• Pre-production parts.
• Diagnostic and surgical operation planning.
 Applications of AM

Manufacturing and Tooling

• Tooling mold parts (soft tooling and hard tooling)
• Casting
• EDM electrodes
• Master models
Industries
• Aerospace
• Jewelry
• Consumer electronics
• Automotive
• Biomedical
• Tableware