Additive Manufacturing 3D printing .pptx

Additive manufacturing

1. Additive manufacturing and composite materials 3D PRINTED JACKSCREW Submitted by Krish A 22101048 Antony Pradeesh 22101018 Nirjara Rao Manish 22101003

2. Table of content Objective Introduction to AM Case studies Material selection Methodology Fabrication Result Conclusion Reference

3. Objectives Understanding the process of additive manufacturing Working of a 3D printer Designing process using a CAD software Material Selection Properties of composite material Slicing Simulation of Design process Layer by Layer printing Principles of DFAM Post processing Advantages of Additive manufacturing over traditional methods 3

4. Introduction to am What is AM? Additive manufacturing is a computer controlled process that creates 3D components by depositing the material layer-by-layer. It is the industrial production method for the 3D printing process. Need of AM Additive manufacturing or AM is a very smart, optimal, effective and cost-time saving process Principle of Additive Manufacturing “Layer by Layer manufacturing” History of AM technology Development of AM technology goes back to 1986 when Chuck Hull patented the technology of stereolithography. From that period, the technology has reached to a level where complete houses can be built in 6 hours ONLY !!! 4

5. Additive manufacturing process Classification of AM There are various methods according to the type of product being manufactured . A few are listed as follows VAT polymerization Material Jetting Fused Deposition Method Electron beam melting Various process applications Rapid Prototyping, Rapid tooling, Rapid manufacturing Industry Application Aerospace Automotive Medical Food 5

6. Case study Additive manufacturing in Aerospace Industry

7. 7 In aerospace engineering, technological innovation is the key to soaring new heights. One such innovation that has revolutionized traditional manufacturing processes within this industry is additive manufacturing. This transformative technology has catalysed a shift in aerospace, offering unprecedented advantages encompassing design, performance, and materials. Freedom of Design This newfound freedom empowers aerospace designers to craft components with optimized shapes with fewer parts without sacrificing structural integrity. Lower Costs Unlike subtractive manufacturing methods, which often result in significant material waste, 3D printing builds components layer by layer, utilizing only the necessary material. This efficiency translates into cost savings through reduced material consumption and less consumption Performance improvement through iteration prototyping This process in the development phase can be instrumental in fine-tuning aerospace components to meet stringent performance and safety requirements. 

8. 8 A GE Aviation team developing 3D-printed parts for the world’s largest jet engine, the GE9X, and preparing them for production. “The beauty and the value of additive manufacturing comes in the flexibility of design and the speed of innovation,” Fuel nozzle tip WHY ADDITIVE?: • Solving for fuel mixing, fuel emissions and cost savings ADDITIVE BENEFITS: • 5X more durable • 20 parts printed as one POWDER: Cobalt-chrome alloy As observed in the above example, GE additive, a subsidiary of GE aviation has switched from traditional method to AM for many such components as show above is Fuel nozzle tip. This shift has increased productivity rapidly.

9. 9 Material selection Material selection is an essential aspect of product design and development. An appropriate material should meet many basic criteria including efficient manufacturability, performance, reliability non-degradability and recyclability as given by the chart We have used PLA – Poly Lactic Acid Polylactic acid (PLA) is a biodegradable, biocompatible, and non-toxic plastic. It has a low melting point and requires less energy during the process. The material was very durable & had precisely printed the Jackscrew

10. 10 Fused deposition method Fused Deposition Modeling (FDM) is a 3D printing technology that uses thermoplastic polymers to create objects in layers. In FDM, a 3D printer extrudes a thermoplastic filament in layers onto a build plate. The filament is heated to a semi-molten state and deposited through a nozzle. The material solidifies into a 3D object. The process is controlled by a computer. In industrial machines, the process takes place in a chamber with a controlled environment and temperature. Our vendor had explained all the major components of the printer and its working

11. 11 Cost-Effective: Affordable equipment and materials. Material Variety: Supports a wide range of thermoplastics. Ease of Use: User-friendly, accessible to beginners. Layered Construction: Allows for complex geometries. Rapid Prototyping: Quick iteration for design validation. No Support Structures (in some cases): Dual extruders or soluble supports reduce the need for manual removal. Customization and Personalization: Easy to customize objects. Desktop Availability: Compact size, suitable for home and small business use. Open-Source Community: Access to a variety of software, firmware, and modifications, fostering innovation. ADVANTAGES OF FDM METHOD

12. Fabrication 12 Step 1 : 3D Model preparation A CAD model of a Jackscrew was designed in AutoCAD, then a slicing software processed the model and then generated the toolpath for the printer Step 2 : Material filament We used thermoplastic element PLA, which is both durable & precise after printing. Step 3 : Heating and Extrusion Extruder of the FDM printer contains as nozzle as shown in the image which heats up, to melt the filament. The nozzle moves along the defined toolpath and the material deposits layer by layer in the shape and orientated earlier provided on the build platform. The process continues until the whole Jackscrew is printed Step 4 : Post processing The printing always leaves a little bit of burns on its surface & uneven surface, which is cleared using a sand paper Step 5 : Component is Ready ! Thus a small model of the Jackscrew used in variety of aircraft applications is additively printed

13. During the Fabrication process & team @ 3d printing vendor 13

14. SUMMARY 14 The project provided us with valuable hands-on experience in the 3D printing process, offering a deeper understanding of the intricacies involved in designing and printing components. While the theoretical knowledge of the Fusion Deposition Method (FDM) was initially challenging, engaging with the machinery firsthand has made the concepts more tangible and applicable for future projects and developments. The practical aspect of the project not only demystified the theoretical aspects but also equipped us with practical insights that will undoubtedly contribute to our proficiency in utilizing 3D printing technologies in future endeavours.

15. References https://www.bing.com/images/search?view=detailV2&ccid=siWsHVYR&id=5F13D6296DB12BA8AF6C4FAC16474E6F37857177&thid=OIP.siWsHVYRC3zwEMVbUpOMYgAAAA&mediaurl=https%3a%2f%2fwww.aircraftspruce.com%2fcache%2f400-400-%2fcatalog%2fgraphics%2f05-06467a.jpg&exph=400&expw=373&q=jack+screw+in+aircraft&simid=608032658010356964&FORM=IRPRST&ck=B6A7C67773AAF04819D1F88E86E59565&selectedIndex=5&ajaxhist=0&ajaxserp=0 https://chat.openai.com/c/59bb12aa-620c-43bd-b58c-77600af6d997 https://www.bing.com/images/search?view=detailV2&ccid=qZ391%2fd0&id=3EB5CB20F554D836685E89121D32E2B6610E4E52&thid=OIP.qZ391_d0bOdnf9zY_MilOAAAAA&mediaurl=https%3a%2f%2fupload.wikimedia.org%2fwikipedia%2fcommons%2fthumb%2f5%2f50%2fAdjustable_stabilizer.svg%2f440px-Adjustable_stabilizer.svg.png&exph=256&expw=440&q=jack+screw+in+aircraft&simid=608036201395083407&FORM=IRPRST&ck=49DB0A50FB7DFC1B56384E44FD2D7543&selectedIndex=1&ajaxhist=0&ajaxserp=0 Creality Ender-3 S1 Pro Desktop 3D Printers - Specifications - 3D Printing

16. THANK YOU Submitted by Krish A 22101048 Antony Pradeesh 22101018 Nirjara Rao Manish 22101003