Liquid Based and Solid Based Additive Manufacturing systems

In this Presentation u will u will process of #Additive Manufacturing

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ADDITIVE MANUFACTURING
(20IP653)
Module-2
Liquid based & Solid based AM systems
Course Instructor
Vijay Praveen P M
Assistant Professor
Department of I&P Engg.

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SYLLABUS
LiquidbasedadditiveManufacturingsystems:Classification
–Liquidbasedsystem–StereolithographyApparatus(SLA)-
Principle,process,advantagesandapplications–Solid
basedsystem–FusedDepositionModeling–Principle,
process,advantagesandapplications,LaminatedObject
Manufacturing.
SolidbasedAMSystems:LaminatedObjectManufacturing
(LOM):ModelsandSpecifications,Process,working
principle,Applications,AdvantagesandDisadvantages,
Casestudies.FusedDepositionModeling(FDM):Models
andspecifications,Process,workingprinciple,
Applications,AdvantagesandDisadvantages,Casestudies.

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Introduction
➢Mostliquid-basedrapidprototypingsystemsbuild
partsinavatofphoto-curableliquidresin,an
organicresinthatcuresorsolidifiesunderthe
effectofexposuretolaserradiation,usuallyinthe
UVrange.
➢Thelasercurestheresinnearthesurface,forming
ahardenedlayer.Whenalayerofthepartis
formed,itisloweredbyanelevationcontrol
systemtoallowthenextlayerofresintobe
similarlyformedoverit.
➢Thiscontinuesuntiltheentirepartiscompleted.
Thevatcanthenbedrainedandthepartremoved
forfurtherprocessing,ifnecessary

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Laser Stereolithography
Apparatus(SLA)
StereoLithography(SL)isthefirstprocessever
developedinrapidprototypingfieldwiththemeaning
of.3-dimensionalprinting.CharlesHulldevelopedand
patentedthecompletedsystemin1986.Thenhe
founded3DSystems,inc.todevelopcommercial
applicationsoftheprocess.
Stereolithographybuildsplasticpartsorobjectsa
layeratatimebytracingalaserbeamonthesurface
ofavatofliquidphotopolymer.Thisclassofmaterials
originallydevelopedfortheprintingandpackaging
industries,quicklysolidifieswhereverthelaserbeam
strikesthesurfaceoftheliquid.

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PrincipleofStereoLithography:
TheSLAprocessisbased
fundamentallyonthefollowing
principles:
(1)Partsarebuiltfromaphoto-
curableliquidresinthat
cureswhenexposedtoa
laserbeamwhichscans
acrossthesurfaceofthe
resin.
(2)Thebuildingisdonelayerby
layer,eachlayerbeing.scanned
bytheopticalscanningsystem
andcontrolledbyanelevation
mechanismwhichlowersatthe
completionofeachlayer.

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WorkingprocessofStereoLithography:
➢SLAshavefourmainparts:atankthatcanbefilledwithliquidplastic(photopolymer),
aperforatedplatformthatisloweredintothetank,anultraviolet(UV)laseranda
computercontrollingtheplatformandthelaser,
➢IntheinitialstepoftheSLAprocess,athinlayerofphotopolymer(usuallybetween
0.05-0.15mm)isexposedabovetheperforatedplatform.TheUVlaserhitsthe
perforatedplatform,"painting"thepatternoftheobjectbeingprinted.Itsscanata
speedof500to2500mm/sec
➢TheUV-curableliquidhardensinstantlywhentheUVlasertouchesit,formingthefirst
layerofthe3D-printedobject.
➢Oncetheinitiallayeroftheobjecthashardened,theplatformislowered,exposinga
newsurfacelayerofliquidpolymer.Thelaseragaintracesacrosssectionoftheobject
beingprinted,whichinstantlybondstothehardenedsectionbeneathit.
➢Thisprocessisrepeatedagainandagainuntiltheentireobjecthasbeenformedandis
fullysubmergedinthetank.
➢Theplatformisthenraisedtoexposeathree-dimensionalobject.Afteritisrinsedwith
aliquidsolventtofreeitofexcessresin,theobjectisbakedinanultravioletovento
furthercuretheplastic.
➢Objectsmadeusingstereolithographygenerallyhavesmoothsurfaces,butthe
qualityofanobjectdependsonthequalityoftheSLAmachineusedtoprintit.
➢Theamountoftimeittakestocreateanobjectwithstereolithographyalsodepends
onthesizeofthemachineusedtoprintit.Smallobjectsareusuallyproducedwith
smallermachinesandtypicallytakebetweensixtotwelvehourstoprint.Larger
objects,whichcanbeseveralmetersinthreedimensions,takedays.

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Advantages
➢Roundtheclockoperation.TheSLAcanbeusedcontinuously
andunattendedroundtheclock.
➢Goodusersupport.Thecomputerizedprocessservesasagood
usersupport.
➢Buildvolumes.ThedifferentSLAmachineshavebuildsvolumes
rangingfromsmalltolargetosuittheneedsofdifferentusers.'
➢Goodaccuracy.TheSLAhasgoodaccuracyandcanthusbe
usedformanyapplicationareas.
➢Surfacefinish.TheSLAcanobtainoneofthebestsurface
finishesamongstRptechnologies.
➢Widerangeofmaterials.Thereisawiderangeofmaterials,
fromgeneral-purposematerialstospecialtymaterialsfor
specificapplications

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Disadvantages
➢Requiressupportstructures,Structuresthathaveoverhangsandundercuts
musthavesupportsthataredesignedandfabricatedtogetherwiththemain
structure.
➢Requirespost-processing.Post-processingincludesremovalofsupportsand
other
unwantedmaterials,whichistedious,time-consumingandcandamagethemodel.
➢Requirespost-curing.Post-curingmaybeneededtocuretheobject
completelyandensuretheintegrityofthestructure.
ApplicationsofSLA:
TheSLAtechnologyprovidesmanufacturerswithcostjustifiablemethodsfor
reducingtimetomarket,loweringproductdevelopmentcosts,gaininggreater
controloftheirdesign
processandimprovingproductdesign.Therangeofapplicationsincludes:
✓ Modelsforconceptualization,packagingandpresentation.
✓ Prototypesfordesign,analysis,verificationandfunctionaltesting.
✓ Partsforprototypetoolingandlowvolumeproductiontooling.
✓ Patternsforinvestmentcasting,sandcastingandmoulding.
✓ Toolsforfixtureandtoolingdesign,andproductiontooling.

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Solid Based AM
•Solid-basedrapidprototypingsystemsare
verydifferentfromtheliquid-basedphoto-
curingsystems.
•Theyarealsodifferentfromoneanother,
thoughsomeofthemdousethelaserinthe
prototypingprocess.Thebasiccommon
featureamongthesesystemsisthattheyall
utilizesolids(inoneformoranother)asthe
primarymediumtocreatetheprototype

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Classification

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Solid sheet systems
Thisisanobsoletetechnologywhichisnotseenwidelyused
nowadays.Exampleofearliestsolidsheetsystemisthelaminated
objectmanufacturing(LOM)systemfromHelisys,USA.This
technologyusesalasertocutoutprofiles,fromsheetpaper,supplied
fromacontinuousroll,whichformedthelayersofthefinalpart.
Laminated object Manufacturing (LOM) process:
ThisprocessisdevelopedbyHelisysofTorrance,
California:USA,in1998whichisalayeradditiveprocess.
Inthisprocess,theMaterialconsistsofpaperlaminated
whichiscoatedwiththermoplasticadhesiveandrolled
uponspools.Asshowninthefig

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Principle
(1)Partsarebuilt,layer-by-layer,bylaminatingeachlayerofpaperor
othersheet-formmaterialsandthecontourofthepartonthatlayer
iscutbyaCO2laser.
(2)Eachlayerofthebuildingprocesscontainsthecross-sectionsof
oneormanyparts.Thenextlayeristhenlaminatedandbuilt
directlyontopofthelaser-cutlayer.
(3)TheZ-controlisactivatedbyanelevationplatform,whichlowers
wheneachlayeriscompleted,andthenextlayeristhenlaminated
andreadyforcutting.TheZ-heightisthenmeasuredfortheexact
heightsothatthecorrespondingcrosssectionaldatacanbe
calculatedforthatlayer.
(4)Noadditionalsupportstructuresarenecessaryasthe“excess”
material,whicharecross-hatchedforlaterremoval,actasthe
support.

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working
➢afeedermechanismadvances
thesheetoverthebuildplatform,
whereabaseismadeupfrom
paperanddouble-sidedfoam
tape.
➢Aheatedrollerappliespressure
tobondthepapertothebase.
➢Cotlasertracestheoutlineof
thecaddatafedinthecomputer.
Afterthelasercuttingis
completedtheplatformmoves
downandafreshsheetof
laminatedpaperisrolledon.The
processisrepeatedasneededto
buildthepart.Lomprocessis
usedinpatternmakingandtoy
designingasthisprocessis
cheaperandhighvolume
productioncanbeachieved.

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Materials
Potentially,anysheetmaterialwithadhesive
backingcanbeutilizedinLaminatedObject
Manufacturing.
Ithasbeendemonstratedthatplastics,metals,
andevenceramictapescanbeused.However,
themostpopularmaterialhasbeenKraftpaper
withapolyethylene-basedheatsealadhesive
systembecauseitiswidelyavailable,cost-
effective,andenvironmentallybegin

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Fused Deposition Modelling (FDM)
•Principle
•TheprincipleoftheFDMisbased
onsurfacechemistry,thermal
energy,andlayermanufacturing
technology..
•Thematerialinfilament(spool)
formismeltedinaspecially
designedhead,whichextrudesonthe
model.
•Asitisextruded,itiscooledandthus
solidifies.Toformthemodel.
•Themodelisbuiltlayerbylayer,like
theotherRPsystems.
•Parameterswhichaffectperformance
andfunctionalitiesofthesystemare
materialcolumnstrength,material
viscosity,positioningaccuracy,road
widths, deposition speed,
volumetricflowrate,tipdiameter,
envelopetemperature,andpart
geometry

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Step1:ThePreparation
Ageometricmodelofaconceptualdesigniscreatedon
CADsoftwarewhichusesIGESorSTLformattedfiles,It
canthenimportedintotheworkstationwhereitis
processedThroughTheQuickSliceandSupportWork
proprietysoftwarebeforeloadingtoFDMsystems.
TheCADfileisslicedintohorizontallayersafterthepart
isorientedfortheoptimumbuildposition,andany
necessarysupportstructuresareautomaticallydetected
andgenerated.Theslicethicknesscanbesetmanuallyto
anywherebetween0.172to0.356mm(0.005to0.014in)
dependingontheneedsofthemodels

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Step2:TheBuild
Thenozzleisheatedtomelttheplasticfilamentandismountedtoa
mechanicalstagewhichcanbemovedinbothhorizontaldirections.
Asthenozzleismovedoverthetableintherequiredgeometry,it
depositsathinbeadofextrudedplastictoformeachlayerandcreate
atwo-dimensionalcrosssectionofthemodel.
Theplastichardensimmediatelyafterbeingsquirtedfromthenozzle
andbondstothelayerbelow.
Theplatformthendescendswherethenextlayerisextrudeduponthe
previous.Thiscontinuesuntilthemodeliscompleted,.Theentire
systemiscontainedwithinachamberwhichisheldatatemperature
justbelowthemeltingpointoftheplastic.
Step3:Post-processing
Onceallthelayersaredrawnandthemodeliscomplete,themodelis
thenremovedfromtheplatform,andthesupportstructuresare
removedfromthepart

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Materials
Materials are available, such as
➢AcrylonitrileButadieneStyrene(ABS)-Standard
prototypingplasticwithdurability,
➢Polycarborate(PC),
➢Polyamide(PA),
➢Polystyrene(PS),
➢Lignin,
➢Rubber,amongmanyothers,withdifferent
trade-offsbetweenstrengthandtemperature
properties.

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Case study-1
1.National Aeronautical and Space Administration (NASA) and Boeing
Rocketdyne Uses LOM TM to Create Hot Gas Manifold for Space
Shuttle Main Engine
One successful example of how an organization implements LOMTM
systems into their design process would be from the Rapid Proto-typing
Laboratory, NASA’s Marshall Space Flight Center (MSFC), Huntville, AL.
Thelaboratorywassetupinitiallytoconductresearchand
developmentindifferentwaystoadvancethetechnologyof
buildingpartsinspacebyremoteprocessingmethods.However,as
MSFCengineersfoundalotmoreusefulapplications,i.e.,productionof
conceptmodelsandproof-outofcomponentdesignsotherthan
remoteprocessingwhenrapidprototypingmachineswereinstalled,the
centersoonbecamearapidprototypingshopforotherMSFCgroups,as
wellasotherNASAlocationsandNASAsubcontractors.

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ThecenteracquiredtheLOM-1015TMmachinefromHelisysin1999
toaddontheirexistingrapidprototypingsystemsandthemachine
wasputthroughitsfirstchallengewhenMSFC’scontractor,Boeing/
Rocketdynedesignedahotgasmanifoldforthespaceshuttle’smain
engine.
Thepartmeasured2.40m(8ft)longand0.10m(4in)indiameter
andwascomplexindesignwithmanytwistsandturnsand“tee”
junctionconnectors.Iftheconventionalmethodofcreatingthe
prototypewereemployed,itwouldrequireindividualsteelpartstobe
weldedtogethertoformtheprototype.
However,therewasalwaysapotentialofleakageatthejointpartand
thus,analternatemethodwasconsidered.Theprototypewastobe
madefromasinglepieceofsteelandsuchasolutionwasnotonly
expensive,theprototypebuiltdidnotfitwelltothemainengineof
thespaceshuttle.

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Eventually,engineersatBoeingdecidedtobuildthepartusingthe
LOMTMprocessatMSFC.TheypreparedaCADdrawingofthedesignand
sentitovertoMSFC.
Thedesignwassectionedintoeightparts,eachwiththeirregularboss-
and-socketbuiltinthemsoastofacilitatejoiningofthepartstogether
uponcompletion.
Thewholebuildingprocesstooktendaystocomplete,includingthree
daysofreworkforflawedparts.
Itwasworkedoncontinuously.OneadvantageofusingtheLOMTM
machineisthatthesystemcanbeleftunattendedthroughoutthe
buildingprocessandifthesystemrunsoutofpaperorthepapergets
jammedwhilebuilding,itisabletoalerttheoperatorviaapager.The
prototypewasthenmountedontotheactualspaceshuttleforfinalfit
checkanalysis.
Itwasestimatedthatthecompanysavedtensofthousandsofdollars,
althoughBoeingdeclinedtorevealtheactualcostsaving.Thewhole
processalsodrasticallyreducesthebuildingtimefromtwotothree
monthstoameretendays.

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Case study-2
•STRATASYS’FUSEDDEPOSITIONMODELING(FDM)
StratasysInc.wasfoundedin1989andhasdevelopedmostofthe
company’sproductsbasedontheFusedDepositionModeling(FDM)
technology.
ThetechnologywasfirstdevelopedbyScottCrampin1988andthepatent
wasawardedintheU.S.in1992.
FDMusestheextrusionprocesstobuild3Dmodels.Stratasysintroducedits
firstrapidprototypingmachine,the3Dmodeler®inearly1992andstarted
shippingtheunitslaterthatyear.Overthepastdecade,Stratasyshasgrown
progressively,seeingherrapidprototypingmachines’salesincreasefromsix
unitsinthebeginningtoatotalof1582unitsintheyear2000[9].

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Important Questions
•1.ExplainwithaneatsketchSLAAMprocess
andalsostateitsadvantages,disadvantagesand
applicationsofit.
•2.ExplainwithaneatsketchLOMAMprocess
andalsostateitsadvantages,disadvantagesand
applicationsofit.
•ExplainwithaneatsketchFDMAMprocessand
alsostateitsadvantages,disadvantagesand
applicationsofit