MAN 547

Reverse Engineering in Mechanical Design

Product Realization
&
Reverse Engineering
Dr. Arafa Soliman
Department of Mechanical Engineering
Product Realization
&
Reverse Engineering
Lecture No. 4

Additive Manufacturing
https://www.youtube.com/watch?v=EHvO-MlzAIM

https://www.youtube.com/watch?v=t4S0mKjXtT4
 Introduction to Additive Manufacturing
Machines for Additive Manufacturing

They can be roughly divided into three machine classes.

Machines that make:

1. concept models are called personal 3D printers

(fabbers),
2. functional prototypes are called professional 3D
printers
3. final products are called production 3D printers.
 Introduction to Additive Manufacturing
Machines for Additive Manufacturing
 Introduction to Additive Manufacturing
Machines for Additive Manufacturing

1. concept models are called personal 3D printers

(fabbers),

Plastic

Fabber Semi Professional

 Introduction to Additive Manufacturing
Machines for Additive Manufacturing

2. functional prototypes are called professional 3D

printers

Plastic

Professional
 Introduction to Additive Manufacturing
Machines for Additive Manufacturing

3. final products are called production 3D printers.

Plastic, metal and ceramics

Production 3D printer
 Additive Manufacturing Processes
Additive manufacturing (AM) is an automated fabrication
process based on layer technology. AM integrates two
main subprocesses:
1. The physical making of each single layer
2. The joining of subsequent layers in sequence
to form the part
 Additive Manufacturing Processes
The standard layer thickness is about 0.1 mm but can be
reduced to 0.016 mm according to the process. Thus, it not
only increases the exactness of the parts, but also the
number of required layers, the data volume, and the
manufacturing time.
 Additive Manufacturing Processes
To generate a physical layer, multiple materials like
plastics, metals, or ceramic materials in the form of
powders, liquids, solids, foils, or sheets can be used.
https://
www.youtube.com/watch?
v=yiUUZxp7bLQ
https://
www.youtube.com/
watch?v=2zvxjzC6prk
https://www.youtube.com/watch?
v=fql_2zRIxI0 https://www.youtube.com/watch?v=g3OUWihMWIQ
https:// https://www.youtube.com/watch?v=97doBH9jSXY
www.youtube.com/watch?
v=Mjf6oaMVWr8
For the process different physical principles such as photo-
polymerization, selective fusing, melting, or sintering,
cutting, particle bonding, or extrusion can be applied.
 Additive Manufacturing Processes
For the outlining of each layer an energy source is
required, providing the necessary physical process, as well
as a positioning system to follow the x-y coordinates.
The following systems are used:
 Additive Manufacturing Processes
For creating a printed layer, the following systems are used:

1. Laser with scanner units

2. Single or multiple nozzles
3. Knives or blades in cutting plotters
4. Electron beams with deflection devices
5. Extruder with x-y-z positioning system

https://www.youtube.com/watch?v=utZZsph6hKA
 Additive Manufacturing Processes
There are basic 5 families of Generative Manufacturing
Processes
 Additive Manufacturing Processes
There are basic 5 families of Generative Manufacturing
Processes (Brand names)
 Additive Manufacturing Processes
1. Polymerization
1.1 Laser stereolithography (LS)
1.2 Polymer Printing and Polymer Jetting
1.3 Digital Light Processing
2. Sintering and Melting
2.1 Laser Sintering/Selective Laser Sintering (LS/SLS)
2.2 Powderbed Fusion (PBF), Selective Laser Melting (SLM)
2.3 Electron Beam Melting
3. Extrusion/Fused Layer Modeling
4. Powder-Binder Process
5. Layer Laminate Manufacturing (LLM)
 Additive Manufacturing Processes
1. Polymerization
The selective polymerization of a liquid resin (of the
epoxy, acrylate, or vinyl ether type) by means of ultraviolet
radiation is called photo-polymerization.
 Additive Manufacturing Processes
1. Polymerization
Various processes exist, which only differ in the way the
UV radiation is generated, and in the method of contouring.
Some polymerization processes result in a partial
solidification only.
Therefore, a green part is produced, requiring additional
treatment to achieve a completely cured part.
 Additive Manufacturing Processes
1. Polymerization
The additional treatment follows after the build process in a
special chamber, called a post-curing oven. This chamber
is equipped with UV lamps, which provide complete and
uniform curing of the part.
 Additive Manufacturing Processes
1. Polymerization
During the generation of the part,
the polymerization processes
require supports. These are
necessary to stabilize and fix the
part, including overhangs, to
keep elements in position that are
not connected to each other and
to avoid deformations like
twisting and warping.

Supports
 Additive Manufacturing Processes
1. Polymerization
The supports are added to
the 3D CAD model by
means of automated
software and have to be
removed manually after
finalizing the complete
part.
Some types of supports
(and materials) can be
washed off automatically
by special cleaning devices.
 Additive Manufacturing Processes
1. Polymerization
1.1 Laser stereolithography (LS)
Stereolithography is the oldest and until
today the most detailed AM process. The
parts are generated by polymerization of the
liquid resin. UV-laser beam used to transfer
the liquid into a solid state (solidified) by
polymerization.
Thus, corresponding to the part’s contour
from CAD, scaled solid layers are formed.
The laser beam is guided by scanning device,
which is directed according to the contour of
each layer.
 Additive Manufacturing Processes
1. Polymerization
1.1 Laser stereolithography (LS)

solidification of a
single layer,
Lowering table

recoating
 Additive Manufacturing Processes
1. Polymerization
1.1 Laser stereolithography (LS)
Example pf product and supporting while printing

Supports
 Additive Manufacturing Processes
1. Polymerization
1.1 Laser stereolithography (LS)
Available materials are: Material
• Epoxy
• Acrylic resins Unfilled Filled

show a comparably by adding of

low strength and microspheres or rice-
resistance against grain-shaped geometric
temperature-related grains made of glass,
deformations carbon, or aluminum

Low Strength Higher Strength

 Additive Manufacturing Processes
1. Polymerization
1.2 Polymer Printing and Polymer Jetting
When monomer material is applied by print heads, the
process is called polymer printing or polymer jetting. It
could be considered as a 3D printing process, but due to the
generation of parts by UV-solidifying of liquid monomers,
it represents a polymerization or stereolithography process.
 Additive Manufacturing Processes
1. Polymerization
1.2 Polymer Printing and Polymer Jetting
The build material is applied directly to the build platform
by means of a multiple-nozzle print head. Simultaneously
the solidification is carried out by a twin light curtain,
which is produced by UV lamps, moving synchronously
with the print head.
 Additive Manufacturing Processes
1. Polymerization
1.2 Polymer Printing and Polymer Jetting
The supports are automatically generated and
simultaneously manufactured by a second set of nozzles by
printing. Thus, every layer contains build as well as
supporting material.
 Additive Manufacturing Processes
1. Polymerization
1.2 Polymer Printing and Polymer Jetting
A significant portion of material is consumed for the rigid
supports. The supporting material can be washed off in
a largely automated finishing process, without leaving
marks on the part.

Helical planetary gears

with functional integration
 Additive Manufacturing Processes
1. Polymerization
1.2 Polymer Printing and Polymer Jetting
By means of photo-sensitive monomers plastic parts are
manufactured in the process. This facilitates materials in
various colors and different hardness. Parts can be
manufactured consisting of two different materials, which
are similar to two-component injection molded parts.
 Additive Manufacturing Processes
1. Polymerization
1.3 Digital Light Processing

This variation of photo-

polymerization works with a
commercial DLP (digital light
processing) projector as UV-
light source.
The complete contour of the
current layer is projected onto
the part and simultaneously the
solidification is initiated.
 Additive Manufacturing Processes
1. Polymerization
1.3 Digital Light Processing
 Additive Manufacturing Processes
1. Polymerization
1.3 Digital Light Processing
The projector is mounted in the lower section of the
machine housing. The resin is stored in a container with a
glass bottom which is positioned above the projector.

The current contour of the

next layer is projected from
below to the lower side of
the glass bottom and thus to
the resin reservoir.
 Additive Manufacturing Processes
1. Polymerization
1.3 Digital Light Processing
A large variety of photo-sensitive plastics, including
biocompatible types, which can be used for the production
of hearing aid housings or master models for dental
prosthesis, is available.