additive manufacturing technology .pptx

additive manufacturing

1. Visvesvaraya Technological University “Jnana Sangama” Belagavi – 590 018 ADDITIVE MANUFACTURING Seminar on Sabarish A 1BI18ME442 For the Academic Year 2020-21 . Under the guidance of , Dr. Vasanth Kumar R Department of Mechanical Engineering BANGALORE INSTITUTE OF TECHNOLOGY K. R. Road, V. V. Puram, Bangalore – 560 004.

2. CONTENTS Objectives Introduction A M process A M technologies Materials used in AM Advantage Disadvantage Applications Scope of AM Reference conclusion

3. OBJECTIVES Encourage domestic manufacturing across the value-chain to promote Make in India. Increase domestic value addition in core and ancillary components, machines, materials and software. Reduce import dependency of domestic market by developing local skill, technology, scale of production. Promote Innovation and Research infrastructure for commercialization of end-user application based industrial AM products suited for domestic and global markets. Strengthen India's collaborations with global AM organizations and Innovation and Research Centers. Create and update innovation roadmap for AM technologies.

4. INTRODUCTION Manufacturing is a process in which raw materials are transformed into finished goods. Types of manufacturing Additive manufacturing 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. Subtractive manufacturing Subtractive manufacturing is a process where an object is produced by removing unnecessary materials from a stock to create the desired geometry

5. ADDITIVE MANUFACTURING PROCESS 1. Generate a 3D model 2. Generation of STL(Stereolithography) file 3. Software slices the 3D model into thin slices 4. Machine builds it layer by layer 5. Cleanup and post curing 6. Final product outcome

6. Sl no Process types Brief Description Related Technology Materials 1 Powder Bed Fusion Thermal energy selectively fuses regions of a powder bed Electron beam melting (EBM), selective laser sintering (SLS), selective heat sintering (SHS), and direct metal laser sintering (DMLS) Metals, Polymers. 2 Directed Energy Deposition Focused thermal energy is used to fuse materials by melting as the material is being deposited Laser metal deposition (LMD) Metals 3 Material Extrusion Material is selectively dispensed through a through Nozzle or orifice Fused deposition modelling (FDM) Polymers 4 Vat Photo polymerization Liquid photopolymer in a vat is selectively cured by light-activated polymerization Stereo lithography(SLA), digital light processing (DLP) Photopolymers 5 Binder Jetting A liquid bonding agent is selectively deposited to join powder materials Powder bed and inkjet head (PBIH), plaster-based 3D printing (PP) Polymers, Foundry Sand, Metals Material Jetting 6 Material Jetting Droplets of build material are selectively deposited Multi-jet modelling (MJM) Polymers, Waxes 7 Sheet Lamination Sheets of material are bonded to form an object Laminated object manufacturing(LOM), ultrasonic consolidation (UC) Paper, Metals Table : The Seven AM Process Categories

7. 1. POWDER BED FUSION Powder bed fusion process uses thermal energy to melt specific points on a layer of metallic powder. The thermal energy – produced from a laser source – melts the powder material, which then solidifies as it cools and this way, each area of the part is manufactured. The part is built up into layers and so this process is repeated for each layer to create the part. After the melting of one layer, the platform lowers, and the powder recoat deposits a new layer. The material used here is polymer and metal in the form of powder.

8. 2. DIRECTED ENERGY DEPOSITION arm with nozzle moves around a fixed object. Material is deposited from the nozzle onto existing surfaces of the object. Material is either provided in wire or powder form. Material is melted using a laser, electron beam or plasma arc upon deposition. Further material is added layer by layer and solidifies, creating or repairing new material features on the existing object.

9. 3. MATERIAL EXTRUSION First layer is built as nozzle deposits material where required onto the cross sectional area of first object slice. The following layers are added on top of previous layers. Layers are fused together upon deposition as the material is in a melted state.

10. 4. VAT PHOTO POLYMERIZATION The build platform is lowered from the top of the resin vat downwards by the layer thickness. A UV light cures the resin layer by layer. The platform continues to move downwards and additional layers are built on top of the previous layer. Some machines use a blade which moves between layers in order to provide a smooth resin base to build the next layer on. After completion, the vat is drained of resin and the object removed.

11. 5. BINDER JETTING Powder material is spread over the build platform using a roller. The print head deposits the binder adhesive on top of the powder where required. The build platform is lowered by the model’s layer thickness. Another layer of powder is spread over the previous layer. The object is formed where the powder is bound to the liquid. Unbound powder remains in position surrounding the object. The process is repeated until the entire object has been made.

12. 6. MATERIAL JETTING The print head is positioned above build platform. Droplets of material are deposited from the print head onto surface where required, using either thermal or piezoelectric method. Droplets of material solidify and make up the first layer. Further layers are built up as before on top of the previous. Layers are allowed to cool and harden or are cured by UV light. Post processing includes removal of support material.

13. 7. SHEET LAMINATION The material is positioned in place on the cutting bed. The material is bonded in place, over the previous layer, using the adhesive. The required shape is then cut from the layer, by laser or knife. The next layer is added. Steps two and three process can be reversed and alternatively, the material can be cut before being positioned and bonded.

14. MATERIALS USED IN AM PROCESS Thermoplastics Thermoplastic polymers are the most popular types of AM materials. Acrylonitrile butadiene styrene (ABS), polycarbonate (PC) and polylactic acid (PLA) each offer distinct advantages in different applications. Water-soluble polyvinyl alcohol (PVA) is typically used to create temporary support structures, which are later dissolved away. Metals Different metals and metal alloys are used in additive manufacturing, which include precious metals like gold and silver to strategic metals like stainless steel and titanium. Ceramics A variety of ceramics including zirconia, alumina and tricalcium phosphate are also used in additive manufacturing. Also, alternate layers of powdered glass and adhesive are baked together to develop entirely new classes of glass products. Bio Materials The biomaterials used in AM applications include the hardened material like silicon, calcium phosphate and zinc to support bone structures as new bone growth occurs. The bio-inks fabricated from stem cells are also being explored by researchers to form blood vessels, bladders and many other human organs. Also 3D Printing of human organs such as liver tissues, kidney, heart etc are being printed using biomaterials and living cells.

15. Advantages Disadvantage Complex shapes can be easily made. High Energy Consumption. Rapid production of prototypes. Limited Materials. Wastage of material is less. Additive manufacturing Technology is Expensive. No storage cost. Printers Aren't that User-friendly. Ability to customize products. Too Much Reliance on Plastic. Better Quality and Automated Time consumption of 3D Printing is high. Creative Designs and Customization freedom High equipment cost and high end products

16. APPLICATIONS OF ADDITIVE MANUFACTURING Medical implants (Dental, Orthopedic) Advances in research Architectural Engineering Construction Automotive Aerospace Industry & Suppliers Machinery (e.g. Turbines, Special Machinery)

17. SCOPE OF ADDITIVE MANUFACTURING

18. REFERENCE Wright, Paul K. (2001). 21st Century manufacturing . New Jersey: Prentice-Hall Inc. Lipson, Hod, Francis C. Moon, Jimmy Hai, and Carlo Paventi . (2007) "3D-Printing the History of Mechanisms." Journal of Science . Wohler's Report 2014 – 3D Printing and Additive Manufacturing State of the Industry, Annual Worldwide Progress Report, Wohler's Associates, 2014. Custom part Net additive fabrication USA, 2009: http://www.custompartnet.com/wu/additive fabrication, Accessed on January 15, 2015 Materials KTN. (2012). Shaping our National Competency in Additive Manufacturing – A Technology Innovation Needs Analysis Conducted by the Additive Manufacturing Special Interest Group for the Technology Strategy Board. Professor John Hart([email protected]), Massachusetts Institute Of Technology(MIT) Hype Cycle for 3D Printing, 2014

19. CONCLUSION Overall, the  additive manufacturing  industry is definitely growing and rapidly becoming a very large industry in many sectors. It emerged as rapid prototyping and was just originally used for the casting of prototypes. Manufacturers could create molds much faster and more precise than before.

20. Guided by, Dr. Vasanth Kumar R Asst. Professor Department of Mechanical Engineering Bangalore Institute of Technology