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1. Introduction to Additive Manufacturing
“Advances in Subtractive and Additive Manufacturing Technologies”
on 04/12/2023 to 09/12/2023 at
Mangalam College of Engineering, Ettumanoor

2. How to make thinks?

4. Introduction to Additive Manufacturing
•According to ASTM F42, additive manufacturing (AM) is
 the process of
creating three-dimensional objects by building them layer by layer.
 It is also
known as 3D printing, layered manufacturing, or additive fabrication.
 
•Additive Manufacturing (AM) refers to a process by which digital 3D
design data is used to build up a component in layers by depositing material.
•The term ‘Rapid Prototyping (RP)’, ‘3D Printing’, ‘Layer Manufacturing’,
‘Solid Freeform Fabrication’, ‘Digital Manufacturing’ etc. are used as
synonym for AM.

7. Historical Perspectives
•The roots of AM can be traced to two technical areas : topography and photo sculpture.
•Topography.A layered method was proposed by Blanther as early as 1890 for making
moulds for topographical relief maps. Both positive and negative 3D surfaces were to be
assembled from a series of wax plates cut along the topographical contour lines

9. Photosculpture
•Photosculpture arose in the 19th century as an attempt to
create exact three-dimensional replicas of any object -
including human forms (Bogart, 1979).
•One, somewhat successful realization of this technology,
was designed by Frenchman François Willème in 1860.
•A subject or object was placed in a circular room and
simultaneously photographed by 24 cameras placed equally
about the circumference of the room. An artisan then carved
a 1/24th cylindrical portion of the figure using a silhouette
of each photograph.

10. •It consisted of taking 24 simultaneous
photographs of the person to be
portrayed in a room prepared for it.
•With these photographs and the aid
of a pantograph the silhouettes of the
model were drawn to the desired
scale.
•These silhouettes were like segments
with which a model was built that
finally an artist would work to give
sufficient detail to the sculpture.

11. Early developments
•1980
–1
st
Patent application for RP technology – Dr. Kodama (Japan), May 1980.
•1983
–Charles Hull invented SLA Rapid Prototyping Machine
•1986
–1
st
patent issued for RP technology –SLA , to Charles W. Hull.
–Charles W. Hull founded ‘3D Systems’.
•1987
–1
st
commercial SLA printer was introduced by 3D Systems.
–Patent filed for Selective Laser Sintering (SLS) by Carl Deckard.
•1989
–Patent issued for SLS
–Patent filed for Fused deposition Modelling (FDM) by Scott Crump.
–Stratasys was founded by Scott Crump and Lisa Crump.
•1992
–Patent issued for FDM to Stratasys

16. Aspect Benefits
Examples
Customization
Highly customizable products tailored
to specific needs.
Custom prosthetic limbs and implants in healthcare, e.g.,
3D-printed dental aligners like Invisalign.
Design Flexibility
Complex geometries and structures
impossible with traditional methods.
Lightweight aerospace components with lattice
structures by GE Aviation.
Material Efficiency
Minimal waste compared to subtractive
methods like machining.
3D-printed jet engine parts using titanium with reduced
material wastage.
Cost-Effectiveness
Reduced tooling costs for small batch
or prototype production.
Rapid prototyping of automotive parts in F1 teams
without the need for molds or dies.
Lead Time Reduction
Faster production cycles for prototypes
and on-demand parts.
NASA’s use of 3D printing for space mission
components, reducing time from weeks to days.
Lightweighting
Enables the production of lightweight
parts with similar or better strength.
Airbus A350 aircraft parts with weight reductions
achieved using AM.
Reduced Inventory
On-demand manufacturing eliminates
the need for large inventories.
Spare parts printed as needed in remote locations, such
as oil rigs or military bases.

17. Aspect Benefits
Examples
Sustainability
Lower energy consumption and
material wastage compared to
traditional methods.
Adidas using AM for eco-friendly footwear production.
Medical Advancements
Customized implants, prosthetics, and
bioprinting for tissue regeneration.
Cranial implants and bioprinted skin grafts for burn
victims.
Innovation in Tooling
Quick fabrication of molds and dies for
small batches or prototypes.
Injection mold inserts for plastic manufacturing.
Material Diversity
Broad range of materials, including
polymers, metals, and ceramics.
3D-printed titanium implants for medical use and high-
performance polymers for aerospace.
Education and Training
Enhanced learning through hands-on
experience with 3D printers.
Engineering students designing and printing functional
prototypes in educational Fab Labs.
Repair and Maintenance
AM can be used to repair damaged
parts.
Turbine blade repair in power generation industries.
Distributed Manufacturing
Enables production in remote or
decentralized locations.
Military or space missions producing spare parts on-
demand using portable 3D printers.
Innovation and Prototyping
Accelerates innovation cycles by
allowing quick iterations.
Prototyping of consumer electronics, such as smartphone
cases and accessories.

18. Aspect Challenges
Examples
Material Limitations
Limited availability of materials for AM processes,
especially for metals and ceramics.
High-performance aerospace alloys like Inconel
or advanced ceramics are challenging to print
due to thermal and mechanical properties.
Difficulty in printing multi-material components.
Multi-material printing, such as integrating
conductive and insulating materials in
electronics, remains complex.
Material properties often differ from conventionally
manufactured parts.
3D-printed titanium implants may lack the same
fatigue strength as forged titanium parts.
Surface Finish
AM parts often have poor surface finish and require post-
processing.
Metal parts produced via SLM (Selective Laser
Melting) often have rough surfaces that require
machining or polishing.
Post-processing increases time and cost.
Aerospace components printed using AM need
extensive polishing and heat treatment to meet
industry standards.
Production Speed
AM is slower than traditional manufacturing for large-scale
production.
Producing automotive parts like panels using
injection molding is faster than 3D printing.
Size Constraints
Limited build volume of AM machines restricts the size of
parts that can be produced.
Large structural parts for shipbuilding or wind
turbines cannot be printed directly and must be
assembled from smaller components.
Energy Consumption
High energy requirements for some AM processes, such as
laser sintering or melting.
SLM and Electron Beam Melting (EBM)
consume significantly more energy compared to
traditional casting methods.
Cost of Equipment
High initial investment in AM machines and materials.
Industrial-grade SLS and SLM printers can cost
upwards of 1 crore, limiting adoption in small
₹
businesses.
Maintenance and operation costs are also high.
Regular calibration and maintenance of
advanced printers like SLA machines increase
operational expenses.

21. Stereolithography

22. Solid Ground Curing

23. • [Kabandana, Giraso Keza Monia et al. “Emerging 3D printing technologies and methodologies for microfluidic development.”
 Analytical methods : advancing methods and
applications
 (2022):]

25. Material Jetting

27. Binder Jetting

29. Selective Laser melting

30. Electron Beam Melting

34. Laminated Object Manufacturing

35. Ultrasonic Consolidation

37. Fused Deposition Modelling

40. Tesselation

42. Thank You