3D Printing Technology and TechniquesPresentation.pptx

3D Printing Technology and Techniques

1. 1 WHAT IS 3D PRINTING

2. 1983 Charles Hull invents Stereolithography (SLA) Charles ‘Chuck’ Hull was the first to develop a technology for creating solid objects from a CAD/CAM file, inventing the process he termed ‘stereolithography’ in 1983. SLA works by curing and solidifying successive layers of liquid photopolymer resin using an ultraviolet laser. The field that came to be known variously as 'additive manufacturing', 'rapid prototyping' and '3D printing' was born. 2 3D Printing Technology Short introduction to the technology History of 3D Printing: The earliest 3D printing technologies first became visible in the late 1980’s, at which time they were called Rapid Prototyping (RP) technologies. This is because the processes were originally conceived as a fast and more cost-effective method for creating prototypes for product development within industry.

3. 3 3D Printing Technology Short introduction to the technology INTRODUCTION: 3D printing or Additive Manufacturing by ASTM (American Society for Testing and Materials ): “Process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies, such as traditional machining” Rapid Prototyping: “ Rapid prototyping, as the name suggests, is producing a prototype quickly and efficiently ” Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or assembly using three-dimensional computer aided design data. Construction of the part or assembly is usually done using 3D printing or "additive layer manufacturing" technology.

4. 4 3D Printing Technology Short introduction to the technology INTRODUCTION: But: Additive Manufacturing (AM) concerns as well some other technologies Powder Injection Moulding (PIM): comprising Metal Injection Moulding (MIM) and Ceramic Injection Moulding (CIM), is an advanced manufacturing technology for the production of complex, high volume net-shape components.

5. 5 3D Printing Technology Short introduction to the technology INTRODUCTION: But: Additive Manufacturing (AM) concerns as well some other technologies Powder Metallurgy Process Powder Manufacturing: Creation of Fine Powdered Materials Powder Blending: Mixing Powders for Desired Properties Compacting: Pressing Powders at Room Temperature (Performed at room temperature) Sintering: Heating Compressed Material in Controlled Atmosphere (Elevated-temperature process, conducted at atmospheric temperature)

6. 6 3D Printing Technology Short introduction to the technology

7. 7 3D Printing Technology Short introduction to the technology INTRODUCTION: But: Additive Manufacturing (AM) concerns as well some other technologies Hybrid ( Additive and Subtractive manufacturing) Laser Cladding what is it ?? Laser cladding is a manufacturing process that deposits a metallic material onto a surface using a laser beam as the heat source. The substance is melted, fused to the surface, and then typically becomes harder and more resistant to wear than the base material. Industries like aerospace, automotive, and tooling commonly use this method.

8. 8 3D Printing Technology Short introduction to the technology Laser Cladding: Why we use it? Applications: Surface restoration and repair of damaged components. Wear- and corrosion-resistant coating. Thermal barrier coating for high-temperature applications. Enhancement of surface properties like hardness and friction resistance. Creation of complex geometries and structures. Additive manufacturing and 3D printing of metal parts .

9. 3D Printing Technology Short introduction to the technolo gy

10. 10 3D Printing Technology Short introduction to the technology Advantages (or Importance of AM) Cost Reduction Only one production machine Replacing multi-parts assemblies with one 3D printed part Weight reduction etc. Time Saving Reducing delivery time Production on demand in any AM equipped facility: no need for worldwide parts transportation All parts are optimized, so faster repairs performed by the crew etc. Modern Manufacturing Industry 4.0 implementation Many martials on one 3D printer Fast iterations of prototyping Remote manufacturing Complex structures and shapes Use of modern materials and parts optimization etc.

11. 11 3D Printing Technology Short introduction to the technology Advantages (or Importance of AM) Environmental Friendly Waste minimization Low power consumption Less machines involved in process No need for global delivery etc. Less Space Production on demand Reduction of warehouse space Less tools and machines Less material on stock etc.

12. 12 3D Printing Technology Short introduction to the technology Disadvantages: Questionable Accuracy Includes material removal (Post processing) Limitations of raw material Considerable effort required for application design and for setting process parameters Material cost Material properties Limitations of size Cost of printers

13. 13 3D Printing Technology Short introduction to the technology APPLICATIONS

14. 14 3D Printing Technology Short introduction to the technology

15. 15 3D Printing Technology Short introduction to the technology AM transform and revolutionize manufacturing in the future Industry 4.0. Demand of AM has expanded from automobile and aircraft to the manufacturing of houses as well as medical, food, and space industries. National Aeronautics and Space Administration (NASA) has been experimenting to achieve effective and efficient 3DP in Zero-G technology. The researchers have been working to produce 3D printed particles in micron level or lesser, to be useful in the production of smaller electronics and batteries. Even, there is a 3D printer on the market (courtesy: Photonic Professional GT) that can manufacture parts no wider than a human hair.  

16. 16 3D Printing Technology Short introduction to the technology “See the difference in the conception of the part” Conventionally designed and produced cast steel nacelle hinge bracket for an Airbus A320 (top) and optimised titanium version of the nacelle hinge bracket made by additive manufacturing technology. Commercial airplanes can have up to several hundred seat belt buckles. A standard buckle weight is around 155g in St. and 120g in Al. With AM the weight was reduced to 68 g in Ti. Saving over the lifetime of an A380: Fuel: 3,300,000 litres CO2 emission: 0.74Mt

17. 17 3D Printing Technology Short introduction to the technology Parts manufacturing Advantage for sport shoe manufacturer is the data exchange between development and production over night. e.g. ADIDAS with the development in Germany and the production side in China. Example for medical application 3D printing can be personalised Giving back life quality

18. 18 3D Printing Technology Short introduction to the technology NASA has carried out parabolic flights that mimic microgravity to test "additive manufacturing“ Many other applications for printing on-site The assembly can be personalised and printed in one process.

19. 19 3D Printing Technology Short introduction to the technology

20. 20 3D Printing Technology Short introduction to the technology

21. 21 3D Printing Technology Short introduction to the technology

22. 22 3D Printing Technology Short introduction to the technology

23. 23 3D Printing Technology Short introduction to the technology The fast packaging solution, French postal The part is scanned in the post office and a cutter is cutting the different layer on site. For her Spring/Summer 2015 collection, presented in Paris, Dutch fashion designer Iris van Herpen unveiled 3D-printed garments and accessories "grown" that explores the interplay of magnetic forces. Her inspiration of this collection came after she visited CERN, and the Large Hadron Collider

24. 24 3D Printing Technology Short introduction to the technology Chocolate printer Concrete Printer Figure Print Orthodontics

25. 25 Additive Manufacturing Short introduction to the technology 3DP TECHNOLOGIES

26. 26 3D Printing Technology Short introduction to the technology 3D Printing Technologies 1. Sintering This is a technology in which the material gets heated, although not till the condition of melting, for creating high resolution products. To carry out direct metal laser sintering (DMLS) process metal powder is used However, thermo-plastic powders are adopted for selective laser sintering (SLS). 2. Melting 3D printing approaches include powder bed fusion (PBF) , electron beam melting (EBM) and direct energy deposition (DED) . These adopt lasers or electron beams for printing objects by softening the materials collectively.   3. Stereolithography Adopts photo-polymerization for creating parts.

27. 27 Additive Manufacturing Short introduction to the technology PROCESSE

28. 28 3D Printing Technology Short introduction to the technology

29. 29 3D Printing Technology Short introduction to the technology

30. 30 3D Printing Technology Short introduction to the technology Major AM (3DP) processes based on Hopkinson and Dickens’ classification AM Processes Liquid Based Powder Based Solid Based Stereolithography (SLA) Jetting Systems Direct Light Processing (DLP) Selective Laser Sintering (SLS) Selective Laser Melting (SLM) Three-Dimensional Printing (3DP) Fused Metal Deposite Systems (FMDS) Electron Beam Melting (EBM) Selective Masking Sintering (SMS) Selective Inhibition Sintering (SIS) Electro photographic Layered (EPL) Manufacturing High Speed Sintering (HSS) Fused Deposition Modelling (FDM) Sheet Stacking Technologies (SST)

31. 31 3D Printing Technologyng Short introduction to the technology Stereolithography (SLA) SL is widely recognized as the fi rst 3D printing process. It was the fi rst commercialised process. It was a laser-based process A photopolymer resin reacts with the laser and cure to form a solid shape product. It is a precise way to produce very accurate parts. Liquid Based AM Processes

32. 32 3D Printing Technology Short introduction to the technology Stereolithography (SLA)

33. 33 3D Printing Technology Short introduction to the technology Digital Light Processing (DLP) It similar to SLA and a 3D printing process that works with photopolymers. The major difference is the light source. DLP uses a more conventional light source, such as an arc lamp, with a liquid crystal display panel or a deformable mirror device (DMD). It is applied to the entire surface of the vat of photopolymer resin in a single pass, generally making it faster than SLA. The one advantage of DLP over SLA is that only a shallow vat of resin is required to facilitate the process, which generally results in less waste and lower running costs. Liquid Based AM Processes

34. 34 3D Printing Technology Short introduction to the technology

35. 35 3D Printing Technology Short introduction to the technology Laser sintering and laser melting (SLS, SLM) SLS, SLM are interchangeable terms for laser based 3D Printing process that works with powdered materials. The laser is traced across a powder bed of tightly compacted powdered material, according to the 3D data fed to the machine, in the X-Y axes. Laser interacts with the surface of the powdered material it sintered, or fuses, the particles to each other forming a solid. As each layer is completed the powder bed drops incrementally. A roller add and smoothens the powder over the surface of the bed for further processing and the same process goes on until the final parts/part formed. Powder Based AM Processes

36. 36 3D Printing Technology Short introduction to the technology

37. Fused Deposition Modelling (FDM) or Fused Filament Fabrication (FFF) Digital Model: Begin with a digital design. Instructions for Printer: Convert design into instructions. Filament Loading: Load filament onto spool. Feeding to Nozzle: Filament is fed to printer nozzle. Heating Nozzle: Nozzle heats up filament. Softening Filament: Filament softens due to heat. Layer by Layer: Build part by stacking layers. Solid Part: Layers fuse into a solid object. 37 3D Printing Technology Short introduction to the technology Solid Based AM Processes

38. Sheet Stacking Technologies (SST) Layered Sheet Stacking: SST builds by stacking thin layers. Sheet Feeding: Sheets fed onto previous layers. Adhesive or Heat: Sheets bond via adhesive or heat. Complex Objects: Forms intricate shapes. Diverse Materials: Works with various materials. Precision: Offers high-level accuracy. Versatile: Useful in various industries. 38 Additive Manufacturing Short introduction to the technology Solid Based AM Processes

39. 39 3D Printing Technology Short introduction to the technology

40. 40 3D Printing Technology Short introduction to the technology Binder Jetting Jetting Technique: Utilizes jet spraying. Binder Jetting: Material sprayed is a binder. Selective Spraying: Binder sprayed onto part material powder. Layer-by-Layer Build: Forms part layer by layer. Powder Bed Smoothing: Roller levels powder for each layer. Fusion Process: Binder bonds layers together. Incremental Bed Drop: Bed lowers after each layer. Smooth Transition: New layer binds with previous layer.

41. 41 3D Printing Technology Short introduction to the technology

42. 42 3D Printing Technology Short introduction to the technology Binder Jetting

43. 43 3D Printing Technology Short introduction to the technology Voxeljet Voxeljet Company: Specializes in industrial 3D printing. Binder Jetting: Uses binder jetting technology. Large-Scale Printing: Focuses on big parts and molds. Foundry Applications: Creates sand molds for casting. Automotive and Aerospace: Produces complex components. Customization: Tailored solutions for industries. Speed and Precision: High-speed production with accuracy. Diverse Materials: Works with various materials.

44. 44 3D Printing Technology Short introduction to the technology MATERIALS

45. 45 3D Printing Technology Short introduction to the technology

46. 46 3D Printing Technology Short introduction to the technology AM Materials Nylon (Polyamide): Used as powder in sintering or filament in FDM. Strong, flexible, and reliable 3D printing material. Natural white, customizable color pre/post printing. Combines with powdered aluminum for Alumide. ABS (Acrylonitrile Butadiene Styrene): Common plastic in FDM filament form. Strong and available in various colors. Widely used in entry-level FDM 3D printers. Filament accessible from multiple sources. PLA (Polylactic Acid): Biodegradable 3D printing material. Used in resin (DLP/SL) or filament (FDM) forms. Offers various colors, including transparent. Less durable than ABS, but eco-friendly.

47. 47 3D Printing Technology Short introduction to the technology AM Materials LayWood: Designed for entry-level extrusion 3D printers. Filament form, wood/polymer composite (WPC). Creates wood-like textures and finishes. Metals in 3D Printing: Aluminum and cobalt derivatives are common. Stainless Steel: Strong for sintering/melting/EBM. Gold and Silver: New metals for direct 3D printing. Titanium: Extremely strong for industrial applications. Processed as powders for sintering/melting/EBM.

48. 48 3D Printing Technology Short introduction to the technology LayWood

49. 49 3D Printing Technology Short introduction to the technology AM Materials Ceramics in 3D Printing: New materials group with varying success. Require traditional firing and glazing after printing. Paper in 3D Printing: Standard A4 paper used in SDL process by MCOR. Unique business model for machine and material. Paper-made models are safe, recyclable and eco-friendly. No post-processing needed. Bio Materials in 3D Printing: ( Metals, Ceramics, Polymers and Composites) Extensive research on 3D printing bio materials. Medical applications: tissues, organs for transplants. Development of lab-grown organs and replacement tissues. Potential food production applications, e.g., lab-grown meat.

50. 50 3D Printing Technology Short introduction to the technology Ceramics in 3D Printing:

51. 51 LASER CUTTING TECHNOLOGY Short introduction to the technology

52. 52 Laser Cutting Machine Short introduction to the technology

53. 53 Laser Cutting Machine Short introduction to the technology A laser is a device that generates light in the form of a laser beam. A laser beam is different from a light beam in that its rays are monochromatic (a single color), coherent (of the same frequency and waveform), and collimated (going in the same direction). Unlike mechanical cutting processes that rely on blades and drills, laser cutting uses a focused laser beam to precisely cut through and shape workpieces.

54. 54 Background of Laser Short introduction to the technology Laser cutting has been used in industry since the 1970. The first common application was for sign-making, mainly cutting acrylic. It is now a significant process in every manufacturing economy

55. 55 Laser Stand For Short introduction to the technology

56. 56 Working Principle of Laser Short introduction to the technology A laser is created when electrons in the atoms in optical materials like glass, crystal, or gas absorb the energy from an electrical current or a light. That extra energy “excites” the electrons enough to move from a lower-energy orbit to a higher-energy orbit around the atom's nucleus.

57. 57 Working Principle of Laser Short introduction to the technology

58. 59 Main Components of Laser Short introduction to the technology Lasers are comprised of three main components: 1. The  energy source  pumps light into a gain medium. It varies according to the type of laser. It could be a laser diode, an electrical discharge, a chemical reaction, a flash lamp, or even another laser. 2. The  gain medium  emits light of a specific wavelength when excited by light. It is said to be the source of optical gain. Lasers are typically named after their gain medium. In a CO2 laser for example, the gain medium is CO2 gas. The  resonator  amplifies the optical gain through mirrors that surround the gain medium.

59. 60 Types of Laser Short introduction to the technology Different types of lasers are needed for these applications. Based on their gain medium, lasers are classified into five main types:  Gas Lasers Solid-State Lasers Fiber Lasers Liquid Lasers (Dye Lasers) Semiconductor Lasers (Laser Diodes)

60. Gas(Carbon dioxide) Lasers A gas laser is a laser in which an electric current is sent through a gas to generate light through a process known as population inversion. Examples of gas lasers include carbon dioxide (CO2) lasers, helium–neon lasers, argon lasers, krypton lasers, and excimer lasers. Applications of gas laser : Gas lasers are used in a wide variety of applications, including holography, laser surgery. CO2 lasers are probably the most widely known gas lasers and are mainly used for laser marking, laser cutting, and laser welding. Carbon Dioxide Lasers

61. Working of laser cutting

62. Properties of laser Diffraction-Limited Focused Spot, High Spatial Coherence. ... High Power. Wide Tuning Range (BMW head light).

63. Advantage of laser Cuts non-ferrous material with ease. Uses less energy when cutting Cuts through the thickest of metals – including mild steel. Cut complex shapes with precise detail.

64. Disadvantages of laser  limitations on material thickness harmful gases and fumes high energy consumption upfront costs

65. Application of laser Laser cutting is used to optimize processes, applications, and production across a wide range of industries including  electronic automotive medical metalworking woodworking printing

66. The Maximum Cutting Thickness of Laser For Different Materials

67. Main Determinating Factors for Maximum Cutting Thickness of Laser Material strength laser cutting power cost Laser power

68. Comparison b/w CNC and LASER CNC cutting uses a router bit to cut shapes out of materials like wood, plastic, or metal. Laser cutting uses a high-powered laser to cut through materials like paper, fabric, or acrylic. Both CNC cutting and laser cutting can be used to create detailed shapes and designs in a variety of materials.

69. 71 Additive Manufacturing Short introduction to the technology Thank you for your attention