History Development of AM systems. Overview of Additive Manufacturing (AM)

INTRODUCTION: History Development of AM systems, Overview of Additive Manufacturing (AM); AM history; Classification of AM; Merits/de-merits and applications of AM process; Brief information on different materials used for AM.

1. BY: Dr. K. SRI RAM VIKAS
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
GAYATRI VIDYA PARISHAD COLLEGE FOR DEGREE AND PG COURSES (AUTONOMOUS)
(Affiliated to Andhra University | Reaccredited by NAAC)
(MBA and UG Engineering B.Tech (CE,CSE,ECE and ME) programs are Accredited by NBA)
ADDITIVE MANUFACTURING

2. UNIT– I: INTRODUCTION: History Development of AM systems,
Overview of Additive Manufacturing (AM); AM history;
Classification of AM; Merits/de-merits and applications of AM
process; Brief information on different materials used for AM.

3. UNIT– II:
LIQUID AND SOLID BASED AM TECHNOLOGIES: Classification – Liquid based
system - Stereo lithography Apparatus (SLA), details of SL process, products,
Advantages, Limitations, Applications and Uses.
Solid based system - Fused Deposition Modeling, principle, process, products,
advantages, applications and uses - Laminated Object Manufacturing.
UNIT-III:
POWDER BASED RAPID PROTOTYPING SYSTEMS: Selective Laser Sintering(SLS) –
principles of SLS process, principle of sinter bonding process, Three Dimensional
Printing(3D) – process, major applications, research and development. Direct shell
production casting(DSPC) – key strengths, process, applications and uses, Laser
Engineered Net Shaping (LENS) , Direct Metal Deposition (DMD)

4. UNIT– IV:
MATERIALS FOR RAPID PROTOTYPING SYSTEMS: Nature of material – type of
material – polymers, metals, ceramics and composites- liquid based materials, photo
polymer development – solid based materials, powder based materials - case study.
UNIT-V:
RAPID TOOLING: Classification: Soft tooling, Production tooling, Bridge tooling; direct
and indirect – Fabrication processes, Applications. Case studies – automotive and
aerospace

5. TEXT BOOKS:
1. Rafiq I. Noorani, Rapid Prototyping, “Principles and Applications”, Wiley &
Sons, 2006. 89
2. Chua C.K, Leong K.F and Lim C.S, “Rapid Prototyping: Principles and
Applications”, Second Edition, World Scientific, 2003.
3.Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct
Digital Manufacturing, Ian Gibson, David W Rosen, Brent Stucker, 2nd Edition,
Springer, 2015

6. Reference books :
1. N.Hopkinson, R.J.M, Hauge, P M, Dickens, “Rapid Manufacturing – An Industrial
revolution for the digital age”, Wiley, 2006
2. Ian Gibson, “Advanced Manufacturing Technology for Medical applications:
Reverse Engineering, Software conversion and Rapid Prototying”, Wiley, 2006
3. Paul F.Jacobs, “Rapid Prototyping and Manufacturing : Fundamentals of
Stereolithography”, McGraw Hill 1993. 4. Pham. D.T., and Dimov. S.S., “Rapid
Manufacturing”, Springer Verlog 2001.
4.Rapid Manufacturing: The Technologies and Applications of Rapid Prototyping and
Rapid Tooling, D.T. Pham, S.S. Dimov, Springer 2001.

7. Course Outcomes:
1.CO 1: Understand the principle methods, areas of usage, possibilities and limitations
as well as environmental effects of the Rapid Prototyping and tooling Technologies.
2.CO 2: Understand the process capabilities of liquid and solid based rapid prototyping
methods
3.CO 3: Understand the process capabilities and advantages of powder based rapid
prototyping techniques
4.CO 4: Select the appropriate material for processing through various rapid
prototyping techniques
5.CO 5: Develop innovative components and products through RP applications and
case studies

12. Definition
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.
(fromtheInternationalCommitteeF42forAdditiveManufacturing
Technologies,ASTM)..
WhatYouSeeIsWhatYouBuild(WYSIWYB)Process
DifferencebetweenRapidPrototypingandAdditive
Manufacturing?

13. AdditivevsSubtractiveManufacturing
➢PartComplexity;
➢Material;
➢Speed;
➢PartQuantity;
➢Cost.

14. AdditivevsSubtractiveManufacturing
Figure:FeaturesthatrepresentproblemsusingCNCmachining.
Source:Gibson,AdditiveManufacturing

15. Source:Gibson,AdditiveManufacturing
GenericAMProcess

16. CADModelintoSTLFormat
STLusestrianglestodescribethesurfacestobebuilt.Eachtriangleisdescribedas
threepointsandafacetnormalvectorindicatingtheoutwardsideofthetriangle,ina
mannersimilartothefollowing:
facetnormal4.470293E027.003503E017.123981E-01
outerloop
vertex2.812284E+002.298693E+010.000000E+00 vertex
2.812284E+002.296699E+011.960784E02 vertex
3.124760E+002.296699E+010.000000E+00
endloop endfacet
Source:Gibson,AdditiveManufacturing

17. GenericAMProcess
Effectsofbuildingusingdifferentlayerthicknesses
Source:Gibson,AdditiveManufacturing

18. OtherRelatedTechnologies
1.Reverseengineeringtechnology
2.Computeraidedengineering(CAE):
3DCADmodel+Engineeringanalysissoftwarepackages
3.Haptic-basedCAD
Source:Gibson,AdditiveManufacturing

19. DifferencebetweenvariousAM
techniques?
✓Techniquesusedforcreatinglayers;
✓Techniquesofbondingthelayerstogether;
✓Speed;
✓Layerthickness;
✓Rangeofmaterials;
✓Accuracy;
✓Cost.

20. Evolution
Source:RoyalAcademyofEngineering

21. Source:RoyalAcademyofEngineering
Evolution

22. Source
Googleimages
CurrentandPotentialindustriesforAdditiveManufacturing

23. ProsandCons

24. Source:SAVINGproject/CrucibleIndustrialDesignLtd.;RolandBerger
Benefits

25. Benefits
Source:RolandBerger

26. Source:RolandBerger
Benefits

27. Oldtoothbrush
Newtoothbrush
Customization:
•Bristlehardness
•Colour
•HandleStyleandshape
•Etc.
Home3DPrinter
Laserscannertoinput
personalizeddata
Future: Home Manufacturing

28. CaseStudies
Source:RoyalAcademyofEngineering

29. WHATISADDITIVEMANUFACTURING?
•Additivemanufacturing(AM)oradditivelayermanufacturing(ALM)istheindustrial
productionnamefor3Dprinting,acomputercontrolledprocessthatcreatesthree
dimensionalobjectsbydepositingmaterials,usuallyinlayers.
•Additivemanufacturingistheprocessofbuildingphysicalobjectsbylayeringmaterialslike
metal,plastic,orconcrete.Itisaprocessthatusesspecialsoftwareandequipment.
•ThesoftwarewillfirstcreateadesignknownasaComputer-AidedDesign(CAD).The
equipmentwillthentakethisCADfileandstrategicallylayermaterial,creatingaphysical
representationoftheCAD.

30. AdditiveManufacturingProcessChain
•FromCADdescriptiontophysicalresult,AMinvolvesseveralsteps.Theprocesswillvary
dependingontheproduct.
•Itislikelythatsmaller,simplerproductsmakeuseofAMonlyforvisualizationpurposes,
whereaslarger,morecomplexproductsmayincorporateAMatmultiplestagesand
iterationsthroughoutthedevelopmentprocess.
•Also,intheearlystagesofproductdevelopment,roughpartsmaybeneeded,andAMis
generallyusedduetoitsrapidfabricationcapability.
•Aspartsadvancethroughtheprocess,theymayneedcleaningandpost-processing(suchas
coatingandsanding)beforetheycanbeused;inthisregard,rapidprototypingisusefuldue
tothecomplexityofformsthatcanbecreatedwithoutinvolvingtooling.

31. AdditiveManufacturingProcessChain

33. AdditiveManufacturingProcessChain
Step 1: CAD
•CAD models that fully describe the external geometry are required for
all AM parts. Any professional CAD solid modelling software can be used to
create this, but the final product must be a 3D solid or surface model. To
create such an image, reverse engineering equipment (for example, laser and
optical scanning) can also be used.

34. AdditiveManufacturingProcessChain
Step 2: Conversion to STL
•Upon completion of the digital model, the STL (Standard Tessellation
Language) file format must be used to create the stereolithography.
•Nearly every CAD system supports this format, which is how AM machines
communicate. The STL file serves as the basis for calculating the slices of the model.

35. AdditiveManufacturingProcessChain
Step3:TransfertoMachine
•Inthethirdstep,theSTLfileistransmittedtotheAMmachine.Asaresultofthis
step,itispossibletoadjustthebuildsothatitispositionedandsized
correctly.AcomputercontrolstheAMmachine.TheAM machineis
controlledbythecomputer,thatcomputeronlygeneratestherequired
instructionintheformofG-codesandM-codesbasedonthegivenprocess
parameters.Itgeneratesinstructionsautomatically,ifanycorrectionisneededfor
thebettermentoftheparttobebuiltitcanbecorrected.

36. AdditiveManufacturingProcessChain
Step4:Setup
•Beforethebuildingstarts,theequipmenthastobesetup.
Thesettingscanconstitutepower,speed,layerthickness,andother
severalparametersrelatedtomaterialandprocessconstraints,etc.

37. AdditiveManufacturingProcessChain
Step5:Build
•ThefifthstepistheactualbuildingoftheCADmodel,meltinglayerbylayer.
•Thisprocesscanbesemiorfullyautomatedbutsomeonlinemonitoringis
oftenconducted,sothatthemachinedoesnotrunoutofmaterialorthatsome
softwareerroroccurs.

38. AdditiveManufacturingProcessChain
Step6:PartRemoval
•Oncethepartismanufacturedithastoberemovedfromtheprocess,
whichisnormallydonemanually.Thismayrequireinteractionwiththe
machine,whichmayhavesafetyinterlocksto ensure,forexample,thatthe
operatingtemperaturesaresufficientlyloworthattherearenoactivelymovingparts.

39. AdditiveManufacturingProcessChain
Step7:Post-processing
•Afterthebuild,thepartmightneedsomepost-processingbeforeitiscompletely
finished.Ofcourse,dependingonthematerialandAMprocessused,some
partsmightneedmachining,cleaning,polishing,removalofsupport
structures,hotisostaticpressing(HIP),andheattreatments.

40. AdditiveManufacturingProcessChain
Step8:Application
•Atthisstage,thepartcanbereadyforuse.Nevertheless,itcouldalsoneed
someadditionaltreatments,likepainting,or assemblingwithother
componentsbeforeitisfullyusable.Forexample,theymayrequireprimingand
paintingtogiveanacceptablesurfacetextureandfinish.Treatmentsmaybe
laboriousandlengthyifthefinishingrequirementsareverydemanding.Theymay
alsoberequiredtobeassembledwithothermechanicalorelectronic
componentstoformafinalmodelorproduct.

41. Applications :WhereisAMused?
•AMisusedtocreateawiderangeofproductsacrossagrowing numberof
industries,including:
1.Aerospace
•AMisparticularlysuitedtoaerospaceapplicationsduetoitsweight saving
capabilityandabilitytoproducecomplexgeometric partssuchasblisks.
2.Automotive
•Avarietyofmaterialsarewidelyadditivemanufacturedfortheautomotive
industryastheycanberapidlyprototypedwhileoffering weightandcost
reductions.

42. Applications :WhereisAMused?
3.Medical
•The medical sector is finding an increasing number of applications for additively
manufactured parts, especially for bespoke custom- fitted implants and devices.

43. Blisk
laserandopticalscanning

44. WhatMaterialscanbeusedinAdditive Manufacturing?
1.Biochemicals
•Biochemicals used in AM include silicon, calcium phosphate and zinc while bio- inks
fabricated from stem cells are also being explored. These materials are generally used for
healthcare applications.
2.Ceramics
•A range of ceramics are used in AM, including alumina, tricalcium phosphate and zirconia
as well as powdered glass which can be baked together with adhesives to create new types of
glass product.

45. WhatMaterialscanbeusedinAdditive Manufacturing?
3.Metals
•A wide variety of metals and metal alloys are used for additive manufacturing, including
gold and silver, stainless steels and titanium amongst others. These can be made to create a
variety of different metal parts, ranging from jewellery to aerospace components.
4.Thermoplastics
•Thermoplastic polymers are the most commonly used of AM materials and include a
variety of types with their own advantages and applications. These include acrylonitrile
butadiene styrene (ABS), polylactic acid(PLA) and polycarbonate (PC) as well as water-soluble
polyvinyl alcohol (PVA) which can provide temporary support before being dissolved.

46. AboutAM
IsAdditiveManufacturingthesameas3dPrinting?
•3Dprintingisasynonymforadditivemanufacturing,theyaretwotermsforthe
sameprocesswhichbothmeanthesamething.However,‘additivemanufacturing’is
generallythetermusedbyindustry.
AreCompaniesusingAdditiveManufacturing?
•Yes,lotsofdifferentcompaniesacrossarangeofindustriesuseadditive
manufacturing,includingthemedicalindustry,aerospaceandmore.Additive
manufacturingisparticularlyusefulformakingcomplexorbespokeparts–
whetherforanewapplicationortoreplaceanoldpartthatmaynolongerbe
available.

47. AboutAM
HowisAdditiveManufacturing different from TraditionalManufacturing?
•Additivemanufacturingisdifferentfromtraditionalmanufacturingasitallowsapart
tobebuiltlayer-by-layer,whereastraditionalmanufacturingoftenrequiresapart
tobemadebyjoiningseparatecomponentsorbymachiningawayunwanted
materialtoproducethepart.

48. AboutAM
WillAdditiveManufacturingReplaceConventionalManufacturing?
•Additivemanufacturingisunlikelytofullyreplaceconventionalmanufacturing
duetothetimetakentomanufactureparts.Conventionalmanufacturingis
stillpreferableforsimpleandeasytoproduceitems,butadditivemanufacturingis
becomingthechosenmethodformanufacturingsmallerbatchesofmorecomplex
parts.

49. About AM
Why is AM Important?
•AM is important for the creation of lighter, complex designs that may be too
difficult or expensive to produce using traditional manufacturing techniques.
Removing the need for moulds, milling or machining, AM offers a range of
advantages for both prototyping and production.

50. About AM
•How will Additive Manufacturing Change the World?
•It allows for the creation of complex design with less material wastage when
compared to parts that require machining, as well as allowing for the creation of
lighter structures.
•When these lighter structures are applied to aerospace or automotive
applications, for example, they lead to fuel savings and the related environmental
(and financial) benefits. AM also allows for the replacement of parts that may
otherwise be impossible to replace, meaning that machines can be repaired rather
than scrapped. In addition to these benefits, AM has also seen a level of
democratisation in manufacturing, as more people set up domestic 3D printing
stations.

51. ClassificationofAMProcesses
•Inthepast,manufacturingbusinessesusedsubtractiveprocesseslike molds,
cutting,anddrillingtocreateproducts.Whileremovingmaterialfroma largerwhole
hasworkedwellbefore,modernadditivemanufacturingprocessesarequickly
replacingthem.
•Accordingtoforecasts,theadditivemanufacturingindustryisexpectedtogrowtoa
staggering$23billionbytheendof2023.
•Additivemanufacturingisthecomputer-controlledprocessofbuildinga3Dobjectby
compilinglayeruponlayerofmaterial,typicallyceramicormetalpowder,onabuild
platformuntilthefinalproductisfinished.Thelayersarehardenedusingheat,acuring
agent,orlasers.

52. ClassificationofAMProcesses
•Sincethismethodisadditive,there’slesswastethanwithsubtractive
manufacturing,andtherefore,lowercosts.
•Thereareprosandconsforeachofthesevenmaintypesofadditive
manufacturing.

53. ClassificationofAMProcesses
WhichTypeofAdditiveManufacturingIsRightforYou?
•Beforeselectinganadditivemanufacturingmethod,it’simportanttothinkabout
whatyouneedfromyourproject.
•Application
•Material
•Complexityofthecomponent
•Costofmanufacturing
•Timeofmanufacturing

54. ClassificationofAMProcesses
WhichTypeofAdditiveManufacturingIsRightforYou?
•Quantity of the components to be produced
•Are you looking for a more budget-friendly option, or do you need to use stronger
build materials?
•Nomatterwhichtypeofadditivemanufacturingyouchoose,it’sessentialto
startwithagood3Ddigitalmodel.

55. ClassificationofAMProcesses

56. ClassificationofAMProcesses
Thereareseventypesofadditivemanufacturing,eachwithitsownprocesses,
methodsoflayering,andequipment.
1.VATPHOTOPOLYMERISATION
•VATPhotopolymerisationisalsoknownasstereolithography.Thistypeof
additivemanufacturingusesavatofliquidphotopolymerresin—whichis
howVATphotopolymerizationreceiveditsname.
•Abuildplatformisloweredfromtheresin’stop,movingdownward,andalaser
beamdrawsashapeintheresin,creatingalayer.Theaveragethicknessofonelayer
isbetween 0.025and0.5mm.Aftereachlayerofresin,itmustthenbecuredusing
ultraviolet(UV)light.

57. ClassificationofAMProcesses
•ThisprocessofphotopolymerizationusesmotorcontrolledmirrorstodirecttheUV
across theresinsurface,causingittoharden.Thesestepsarerepeatedtoaddlayers.
•Forincreasedaccuracyandfinish,mostequipmentusesbladesthatgoovereach
layertoremovedefectsbeforeapplyingandcuringthenextlayer.Usingaliquid
createsagreatdealofaccuracyanddetailinthefinishedproject;however,itlacks
thestructuralsupportprovidedbyothertypesofadditivemanufacturing.Thisis
correctedbyaddingsupportstructures.AlthoughtheVATphotopolymerization
processisquicktocomplete,theclean-upandpost-processingtimeislengthy.
•VATPhotopolymerisationisusedinseveralindustriestocreatepartsand
productsrangingfromhearingaidstoNikeshoes.

58. Nike's Air Max 1000 Showcase Advanced 3D Printing in Footwear - 3D Printing
Industry

59. The process used to cure photopolymer liquid resin in a vat layer by layer, turning it
into hard plastic parts using an ultraviolet (UV) laser. The three most common types of
this technology include Stereolithography, Digital Light Processing (DLP), and
Continuous Digital Light Processing (CDLP).
Advantages of Vat Photo Polymerization
•High level of accuracy and good finish
• Relatively quick process
•Large build areas

60. Disadvantages of Vat Photo Polymerization
•Relatively expensive
• Lengthily post-processing time and removal from resin
• Limited to photo-resins materials
•Can still be affected by UV light after print
•May require support structures and post-curing for parts to be strong enough for
structural use

61. ClassificationofAMProcesses
2.MATERIALJETTING
•Withmaterialjetting,theprintheadisabovetheplatform,andmaterialis
depositedontothesurfaceintheformofdroplets.Hundredsofmicro-droplets
arepositionedwithchargeddeflectionplates,providingincreasedcontrol
andaccuracy.Thesedropletsthensolidify,creatingalayer.Thisisrepeated,
buildinguplayers.
•ThedropletsmaybedistributedcontinuouslyorindividuallyusingtheDrop-on-
Demand(DOD)method.Thismethodissimilartoaninkjetprinter.Material
jettingcanbedonewithvariousmaterials,includingpolymersandwaxes.

62. ClassificationofAMProcesses
•Thistypeofadditivemanufacturingisprecise,andyoucanuse
multiplematerialsforoneproject.Althoughaccurate,itisnotthe
mostefficientmethodastimeisspentre-fillingthereservoirthat
depletesquickly.
•Materialjettingisoftenusedtocreaterealisticmodelsorprototypes.

63. A process where droplets of wax-like materials are selectively deposited on a build
platform. The material cools and solidifies, allowing layers of materials to be placed on
top of each other. After the build, support structures are either mechanically removed or
melted away.
Advantages of Material Jetting
• Material jetting can achieve outstanding accuracy and surface finishes
• Parts are good for use in patterns for casting
Disadvantages of Material Jetting
• Limited number of wax-like materials available
• Parts are fragile because of wax-like materials
• Slow build process

64. ClassificationofAMProcesses
3.BINDERJETTING
•Thistypeofadditivemanufacturingusesabinderandapowder-based
material.Thispowder-basedmaterialisappliedtothebuildplatform
witharoller,andthentheprintheaddepositsthebinderontop.
•Thebinderadheresthelayerstogetherandisusuallyinliquidform.
Followingalayer,theproductisloweredontheplatform.Thisis
repeatedtocreatemorelayersuntiltheproductisfinished.When
usingthisprocess,youcanusedifferentmaterials,including
polymers,ceramics,andmetals.

65. ClassificationofAMProcesses
•Binderjettingisconsideredoneofthespeediestadditive
manufacturingmethodsandallowsforcustomization.Forexample,if
yourequirematerialofaspecificquality,youcanchangethebinder-
powderratio,orifyouwanttocreateaproductthathascolorvariation,
youcandoso.
•Oneofthedrawbacksofbinderjettingistheincreaseinpost-processing
time,anditmaynotbethebestchoiceforcreatingstructuralparts.
•Binderjettingisusedinindustrialapplications,dentalandmedical
devices, aerospacecomponents,partcasting,luxuryapplications,and
more.

66. Advantages of Binder Jetting
•Ability to make parts with a range of different colours
•Uses a range of materials: metal, polymers, and ceramics
• Faster AM process
•No warping or shrinking of parts
•Less waste by reusing any unused powder
• Features a two-material method that allows different binder-powder combinations
Disadvantages of Binder Jetting
•Parts require post-processing which adds significant time to the overall process
• Low part strength, not always suitable for structural parts
•Less accurate then Material Jetting

67. 4.MATERIALEXTRUSION
•Materialextrusionisatypeofadditivemanufacturingprocessoftenusedin
inexpensiveat-home3Dprinterswherethematerialisdrawnthroughanozzle,
heated,andthendepositedinacontinuousstream.
•Thisnozzlemovesalonghorizontallyandtheplatformmovesup,down,and
vertically.Thisishowthelayersarecreated.
•Becausethematerialisheated(melted)whenitisapplied,itfusestotheprevious
layer.Thebondingbetweenlayerscanalsobecontrolledthroughtemperature
andchemicalagents.
Classification of AM Processes

68. ClassificationofAMProcesses
•Althoughmaterialextrusionisoftenseenininexpensivemodels,ithasmany
capabilities.Polymersandplasticscanbeused,whichprovidestrongstructural
support.However,therearealsolimitationstothisadditivemanufacturing
process.
•Accuracyisreducedbecauseofthenozzlethickness.
•Materialextrusionisalsooneoftheslowertypesofadditivemanufacturing.
•Manyautomotivecompaniesusematerialjettingtocreatemanufacturing
devicesusedinassemblylines.

69. Advantages of Material Extrusion
•Wide selection of print material
•Easily understandable printing technique
•User-friendly method of print material change
•Low initial and running costs
•Faster print time for small and thin parts·
•Printing tolerance of +/- 0.1 (+/- 0.005")
•No supervision required
•Small equipment size
•Low-temperature process

70. • Visible layer lines
• Extrusion head in continuous motion or the material bumps up
• Supports may be required
• Weak part strength along Z-axis
• Increased print time with finer resolution and wider areas
• Susceptible to warping and other temperature fluctuation issues
• Toxic print materials
Disadvantages of Material Extrusion

71. ClassificationofAMProcesses
5.POWDERBEDFUSION
•Forpowderbedfusionadditivemanufacturing,alayerofpowderisappliedtothe
platform.Athermalenergysourcelikeanelectronbeamorlaserfusesthepowder
beforeasecondlayerisappliedwitharollerorblade.Thislayeringprocessis
thenrepeated.
•Thereareslightvariationswithinpowderbedfusion,including:
•SelectiveLaserMelting(SLM)
•SelectiveLaserSintering(SLS)
•ElectronBeamMelting(EBM)
•DirectMetalLaserSintering(DMLS)

72. ClassificationofAMProcesses
•Despitethedifferencesbetweenthesevariants,allpowderbedfusion
manufacturingoccursinanear-vacuum,pre-heatedchamberwithinert
gas.Metalsandpolymerpowdermaterialscanbeused,whichactasa
supportstructure,makingitasuitabletypeforprototypesandvisualmodels.
•Therearesomedisadvantagestothepowderbedfusionmethodasitrequires
moretimetocompleteprojects;however,thisadditivemanufacturingprocessis
stillusedinvariousindustries,includingaviation,tocreatepartsofajetengine.

73. Advantages of PBF
•Low cost of machines
•No or minimum support structures needed for the build
•Variety of material selection
•Multiple materials can be used
•Capable of recycling powder
Disadvantages of PBF
• Slow and long print time
• Additional post-processing time
• Weaker structural properties
•Variations of surface texture quality
•Support build plate may be needed to avoid warping
•Speed of the print process can determine if the powder is recyclable
•Thermal distortion, mainly for polymer parts
•Machines use a lot of energy to create parts

74. ClassificationofAMProcesses
6.SHEETLAMINATION
•Sheetlaminationisaprocessthatbindslayersusingultrasonicwelding
oranadhesive.
•Therearetwovariationsofsheetlamination;ultrasonicadditivemanufacturing
(UAM)andlaminatedobjectmanufacturing(LOM).Thedifferencebetweenthe
twoisfoundinthematerialusedandthebonding process.
•UAMusesmetalthatisboundtogetherwithultrasonicwelding.
•LOMusespaperthatisboundtogetherusinganadhesive.

75. ClassificationofAMProcesses
•Sheetlaminationisdonebyplacingthematerialonacuttingbed.Layersare
appliedandbondedtothatmaterial.andtheshapeiscutwithaknifeorlaser.
Thisprocesscanbinddifferentmaterialsandisrelativelylowcostandspeedy.
•Accuracyissometimeslackinginsheetlaminationandmayprojectsthatutilize
thisadditivemanufacturingprocessmayrequirepost-processing.Sheet
laminationisoftenusedforprototypes.

76. Sheet lamination can be categorized into seven types:
•Laminated Object Manufacturing (LOM)
•Selective Lamination Composite Object Manufacturing (SLCOM)
•Plastic Sheet Lamination (PSL)
•Computer-Aided Manufacturing of Laminated Engineering Materials (CAM-LEM)
•Selective Deposition Lamination (SDL)
•Composite Based Additive Manufacturing (CBAM)
•Ultrasonic Additive Manufacturing (UAM)
While the types of sheet lamination differ slightly, the overall principle is the same. The
process starts with a thin sheet of material being fed from the roller or placed onto the
build platform.
The next layer may or may not be bonded to the previous sheet, depending on the
process. Layering continues until it achieves the full height. Removal of the print block
and all the unwanted outer edges complete the object.

77. Advantages of sheet lamination
• Relatively low cost
•Larger working area
•Full-colour prints
•Integrates as hybrid manufacturing systems
• Ease of material handling
•Ability to layer multiple materials
•No support structures needed
•In some sheet lamination Depending on technique type used, the material state
remains unchanged
•Faster print time, but does require post-processing

78. Disadvantages of sheet lamination
•Layer height can't be changed without changing the sheet thickness
•Finishes can vary depending on the material and could require post-
processing
•Limited material options available
•Removal of excess material after the laminating phase can be difficult and
time-consuming
•Can generate more waste in comparison to other AM methods
• Hollow parts are challenging to produce in some types of sheet lamination
•Bonding strength is dependent on the laminating technique used

79. 7.DIRECTEDENERGYDEPOSITION
•DirectedEnergyDeposition(DED)isoneofthemostcomplextypesof
additivemanufacturing.Afour-orfive-axisarmwillmovearound,
depositingmeltedmaterialaroundafixedobject.Thematerialismeltedbyan
electronbeamorlaserandwillthensolidify.
•MetalpowderorwiresarethemostcommonmaterialusedwithDED,but
ceramicsandpolymersmayalsobeused.
•Youcanachieveahighdegree ofaccuracyduetotheabilitytorepairand
controlgrainstructureinDED.
Classification of AM Processes

80. •Thefinishvariesbasedonthematerialused.Inthecaseofmetal,
apowderwillprovideamuchbetterfinishthanwire;however, you
can achieve your desired effect with wire through post-processing.
•DirectEnergyDispositionisoftenusedtorepairorfabricateparts.
Classification of AM Processes

81. Advantages of DED
•Strong and dense parts
•Fast build rates
•Reduction in material waste
•Range of material selection: metal, ceramic, and polymer
•Materials are easily changed out
•Ability to make parts with custom alloys
•Parts built to near net shape
•Capability to build larger parts

82. Disadvantages of DED
•Capital cost for systems are high
•Parts have lower resolution resulting in poorer surface finish,
requiring secondary processing
•Support structures are not usable during the build process

84. Materials Used in Additive Manufacturing

85. Polymers in Additive Manufacturing
Materials:
•Thermoplastics: ABS, PLA, PC, Nylon (PA), PEEK
•Photopolymers: UV-curable resins (epoxy, acrylic-based)
•Elastomers: TPU, TPE for flexible parts
Suitable AM Techniques:
•Fused Deposition Modelling (FDM) – ABS, PLA, Nylon
•Selective Laser Sintering (SLS) – Nylon, TPU
•Stereolithography (SLA) – Photopolymers
•PolyJet Printing – Elastomers and digital materials

86. Applications:
•Rapid prototyping
•Visual models
•Jigs & fixtures
•Functional components (Nylon gears, clips)
•Medical devices (PLA/PEEK scaffolds)

87. Metals and Alloys in AM
Materials:
•Stainless Steel (316L, 17-4PH)
•Titanium Alloys (Ti-6Al-4V)
•Aluminium Alloys (AlSi10Mg)
•Nickel Superalloys (Inconel 625, 718)
•Cobalt-Chrome Alloys

88. Suitable AM Techniques:
•Selective Laser Melting (SLM) – Ti, Al, SS, Inconel
•Direct Metal Laser Sintering (DMLS) – SS, Ti, CoCr
•Electron Beam Melting (EBM) – Ti-6Al-4V, CoCr
•Directed Energy Deposition (DED) – Large metal
parts and repair
•Binder Jetting + Sintering – SS, tool steels

89. Applications:
•Aerospace structural parts (lightweight)
•Dental and orthopaedic implants (Ti, CoCr)
•High-temperature turbine blades (Inconel)
•Injection moulds, tools
•Heat exchangers

90. Ceramics in AM
Materials:
•Oxides: Alumina (Al₂O₃), Zirconia (ZrO₂)
•Non-oxides: Silicon carbide, Silicon nitride
•Bioceramics: Hydroxyapatite, Tricalcium phosphate
Suitable AM Techniques:
•Stereolithography (SLA) with ceramic-filled resins (followed
by sintering)
•Binder Jetting + Sintering
•Robocasting/Direct Ink Writing – ceramic pastes

91. Applications:
•Dental crowns, bridges
•Biomedical bone scaffolds
•Wear-resistant parts
•High-temp insulation
•Catalyst supports

92. Composites in AM
Materials:
•Polymer Matrix + fibers (Carbon fiber, Glass fiber, Kevlar)
•Metal Matrix Composites (MMCs) (in R&D stage)
Suitable AM Techniques:
•FDM – with fiber-reinforced filaments
•SLS – with short fiber-reinforced polymers
•Material Extrusion (CFR FDM) – Continuous fiber 3D printing

93. Applications:
•Aerospace brackets and shells
•Sporting goods (bike frames, helmets)
•Robotics arms and frames
•Lightweight structural components

94. Biomaterials in AM
Materials:
•Polymers: PLA, PCL, PMMA, PEEK
•Metals: Ti-6Al-4V, CoCr, SS 316L
•Bioceramics: Hydroxyapatite, β-TCP
Suitable AM Techniques:
•SLA, Inkjet Bioprinting – hydrogels, soft tissues
•FDM – PLA, PEEK implants, biodegradable scaffolds
•SLM/EBM – Titanium implants
•Robocasting – ceramic bone structures

95. Applications:
•Orthopaedic implants
•Dental prosthetics
•Bone scaffolds
•Tissue engineering (experimental)
•Drug delivery devices

96. Other AM Materials
Materials:
•Sand – for moulds and cores
•Wax – for lost wax casting patterns
•Paper, Laminates – in LOM
•Food (chocolate, dough) – specialty AM
• Suitable AM Techniques:
•Binder Jetting – Sand moulds
•Material Jetting – Wax for casting
•Sheet Lamination – Paper, polymer sheets

97. Applications:
•Casting Moulds and cores
•Jewellery casting patterns
•Architectural models
•Edible 3D printing (cakes, designs)

98. Merits (Advantages) of Additive Manufacturing
1. Complex Geometry with No Extra Cost
•AM allows fabrication of intricate geometries, including undercuts, internal
channels, lattice structures, and organic forms.
•Complexity does not increase cost significantly (unlike machining or
casting).
2. Mass Customization
•Products like prosthetics, dental implants, or hearing aids can be
customized for individual users without altering the production system.
•Ideal for personalized medicine and tailored consumer products.

99. 3. Material Efficiency
•AM uses only the material needed for the part, leading to minimal waste.
•Especially beneficial for expensive materials like titanium or superalloys.
4. Tool-less Production
•Eliminates the need for moulds, dies, and fixtures.
•Reduces cost and lead time, especially for low-volume production or
prototyping.

100. 5. Rapid Prototyping and Fast Iteration
•Designers can test and refine prototypes quickly.
•Shortens the product development cycle and speeds up innovation.
6. Consolidation of Parts
•Multiple components can be combined into a single, monolithic part.
•Reduces assembly time, potential failure points, and part count.

101. 7. On-Demand and Decentralized Manufacturing
•Products can be made where and when needed.
•Suitable for remote locations, space missions, military deployment, and
local production hubs.
8. Digital Inventory
•Spare parts can be stored as digital files and printed when needed,
saving storage space and costs.

102. Demerits (Limitations) of Additive Manufacturing
1. Slow Production Speed
•AM is a layer-by-layer process, which can be time-consuming.
•Not efficient for mass production of identical items.
2. High Cost of Machines and Materials
•Industrial AM systems (especially for metals) are expensive to purchase
and maintain.
•Materials (e.g., metal powders) are costlier than bulk forms.

103. 3. Limited Range of Materials
•Fewer material options than traditional manufacturing.
•Some AM materials may not match the mechanical, thermal, or
chemical properties of conventionally processed counterparts.
4. Surface Finish and Dimensional Accuracy
•AM parts often require post-processing (e.g., machining, polishing) to
achieve acceptable surface finish or tight tolerances.
•Some processes leave visible layer lines.

104. 5. Mechanical Anisotropy
•Parts can exhibit different mechanical properties depending on build
orientation (Z-direction is typically weaker).
•This limits performance consistency.
6. Support Structure Removal
•Many AM processes require support structures for overhangs.
•Their removal adds labour, may damage parts, and generates waste.
7. Design Constraints
Although geometrically flexible, designs still need to consider process
limitations (e.g., overhang angles, support access, minimum wall thickness).

105. Detailed Applications of Additive Manufacturing
1. Medical and Healthcare
•Patient-specific implants: Titanium hip joints, cranial plates.
•Dental applications: Crowns, bridges, surgical guides.
•Tissue engineering: Bioprinting of scaffolds with cells.
•Surgical planning models: 3D printed organ models based on CT/MRI
data.

106. 2. Aerospace
•Lightweight structures: Topology-optimized brackets and supports.
•Fuel nozzles and ducts: Complex internal passages for fluid flow.
•Rapid tooling: Fixtures and jigs for aircraft assembly.
•Parts consolidation: Reducing part count increases reliability.
3. Automotive
•Concept car prototyping: Interior/exterior models.
•Tooling: Custom jigs, fixtures, and gauges.
•Racing: Lightweight, aerodynamic custom parts.
•Aftermarket parts: Legacy components for vintage cars.

107. 4. Manufacturing Aids and Tooling
•Conformal cooling channels in injection moulds.
•Custom fixtures and gauges: Produced quickly and inexpensively.
•Replacement parts: On-site printing of wear components.
5. Education and Research
•Physical models of mechanical components.
•Complex structures for research experiments.
•Prototyping for student design projects and innovation labs.

108. 6. Consumer Products
•Eyewear and footwear: Customized and fashionable.
•Jewellery: Intricate designs using wax patterns or direct metal printing.
•Toys and gadgets: Personalized or artistic designs.
7. Art, Architecture, and Heritage
•Architectural models: Precise scale replicas.
•Art installations: Complex geometries and forms.
•Restoration: Reproducing missing or damaged parts in sculptures and
artifacts.

109. 8. Emerging Fields
•Food printing: Customized chocolate, pasta, or meat substitutes.
•Construction: Large-scale AM of concrete structures.
•Bioprinting: Living tissues and organs (experimental stage).

110. History of Additive Manufacturing (AM)
1980s – The Birth of AM
•1981 – Hideo Kodama (Nagoya Municipal Industrial Research Institute, Japan)
proposed a photopolymer-based rapid prototyping system.
•1984 – Charles Hull (USA) invented StereoLithography (SLA), using UV
lasers to solidify layers of photopolymer resin.
•1986 – Hull founded 3D Systems, which became the first commercial AM
company.
•1988 – SLA-1, the first commercial 3D printer, was released.
•1988 – Carl Deckard developed Selective Laser Sintering (SLS) at the
University of Texas.

111. Parallel Developments
•Carl Deckard at the University of Texas developed Selective Laser
Sintering (SLS).
•Scott Crump, founder of Stratasys, developed Fused Deposition
Modeling (FDM) in the late 1980s.
•Helisys developed Laminated Object Manufacturing (LOM).
•MIT’s 3D Printing (3DP) technology (a form of binder jetting) emerged
in the early 1990s.

112. 1990s – Rapid Prototyping Era
•Term Rapid Prototyping (RP) became popular, focusing on fast creation of
design models.
•Commercialization of new technologies:
•Fused Deposition Modelling (FDM) by Stratasys (Scott Crump)
•Laminated Object Manufacturing (LOM) by Helisys
•3D Printing (3DP) technology patented at MIT (Binder Jetting)
•Use was mostly limited to prototyping in automotive, aerospace, and design
firms.

113. 2000s – Transition to Manufacturing
•AM evolved beyond prototyping to include functional parts and tooling.
•Metal Additive Manufacturing gained traction:
•Direct Metal Laser Sintering (DMLS) – EOS
•Electron Beam Melting (EBM) – Arcam
•Medical applications like customized implants and dental components
gained acceptance.
•STL file format became the de facto standard for AM data exchange.

114. 2010s – Industrial Maturity
•Shift from RP to Additive Manufacturing (AM) and Direct Digital
Manufacturing (DDM).
•Standardization efforts started:
•ASTM F42 and ISO/ASTM 52900 defined 7 AM process categories.
•Large players entered the field: HP (Multi Jet Fusion), GE (acquired Arcam
and Concept Laser).
•Applications expanded: aerospace brackets (Airbus, Boeing), orthopedic
implants, automotive parts.

115. 2020s – Mainstream and Innovation
•Integration with Industry 4.0, IoT, and digital twins.
•Development of multi-material, 4D printing, cold spray AM, and hybrid
AM systems.
•Growth in bioprinting, food printing, and construction printing.
•Wider adoption in supply chain decentralization, on-demand
manufacturing, and digital inventories.

116. Current Trends
•Focus on sustainability, recyclable materials, and closed-loop
material systems.
•AM is increasingly adopted in mass production (e.g., dental aligners,
footwear midsoles).
•AI and simulation tools are being used for design for AM (DfAM)
optimization.

117. Terminology
•The field was initially called Rapid Prototyping (RP) because of its use
in producing design prototypes.
•Later it evolved into Rapid Tooling and Rapid Manufacturing.
•The term “Additive Manufacturing” (AM) was adopted to describe
broader production applications, particularly in metals.

118. Historical development of Rapid Prototyping and related technologies

119. Parallels between geometric modelling and prototyping

121. Layering: The process of building an object layer by layer, which is a fundamental
aspect of most AM techniques.
Additive Manufacturing (AM): The process of creating objects by adding material
layer by layer, as opposed to subtractive manufacturing.
Slicing: Dividing a 3D model into thin horizontal cross-sections to guide the AM
process.
Build Envelope: The maximum dimensions within which an AM machine can create
objects.
Resolution: The level of detail or fineness in which an AM system can produce
features.
Commonly Used Terms in Additive Manufacturing (AM):

122. Support Structures: Temporary structures used to hold up overhanging or complex
features during the AM process.
Build Time: The time required to complete the layering and fabrication of a prototype.
CAD (Computer-Aided Design): The use of computer software to create detailed 3D
models.
CAM (Computer-Aided Manufacturing): The use of computer software to control
machinery in manufacturing processes.
STL File: A standard file format used in RP that represents a 3D object's surface
geometry using triangles.

123. Additive Manufacturing
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 (left) 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.

124. The hinge is used to hold the engine nacelle cowling when opened. You can see four of them (older
versions) on top of the open cowing in the image below:

125. Part manufacturing
Advantage for sport shoe manufacturer is
the data exchange between development
and production over night.
e.g. ADIDAS with the development in
Germany an the production side in China.

Example for medical application
3D printing can be personalised
Giving back life quality

126. The assembly can be
personalised and printed
in one process.
NASA has carried out parabolic
flights that mimic microgravity to test
"additive manufacturing”
Many other applications for printing
on-site

127. 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

128. Chocolate printer
Concrete Printer
Figure Print

129. Additive Manufacturing
CAD Model
Preparation
Build Process
Post Process
PART
CAD Design
CAD Translator
File
Verification
Orientation
Support
Parameters
Part Build
Cleaning
Support remove
Post curing
Material
Chemical
properties
Physical
properties

130. Easy Cutting Path
Angled surfaces

131. Supports
Holes

132. Down Ward FacingSurfaces