Additive Manufacturing
Dr. Ratnesh Kumar Raj Singh
Associate Professor
Thapar Institute of Engineering & Technology
Patiala, Punjab
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.*
❖“What You See is What You Build Process”.
*from the International Committee F42 for Additive Manufacturing Technologies.
What is Additive Manufacturing?
➢ The process of joining materials to make objects from 3D model
data, usually layer by layer
➢ “Design for manufacturing to manufacturing for design”
➢ Commonly known as “3D printing”
➢ Manufacturing components with virtually no geometric limitations
or tools.
➢ Distinguished from traditional subtractive machining techniques
Functional principle
✓ The system starts by applying a thin layer of the powder material to the
building platform.
✓ A powerful heat source (laser beam) then fuses the powder at exactly the
points defined by the computer-generated component design data.
✓ Platform is then lowered and another layer of powder is applied.
✓ Once again the material is fused so as to bond with the layer below at the
predefined points.
Additive Manufacturing vs 3D Printing
✓ In the industry, the two terms used interchangeably
✓ AM is the broader and more all-inclusive term.
✓ It is commonly associated with industrial applications, like the
fabrication of functional prototypes.
✓ AM also involves end-use applications like the mass production of
components.
✓ 3D printing is a process of building an object one thin layer at a time.
It is fundamentally additive rather than subtractive in nature.
Advantages of Additive Manufacturing
✓ Complicated geometries which cannot be created by
conventional processes can be easily produced with AM
✓ Reduces the lead time of the manufacturing products
✓ Saves on Energy and Costs
✓ Can handles various types of materials including metals,
polymers, wax and ceramics
✓ Ease of material change
✓ It has capability of manufacturing near net shape components
✓ Less material wastage
✓
7
Easy to change or revise versions of a product
Challenges in Additive Manufacturing
✓ Availability of suitable materials remains one of the biggest
challenge
✓ Integrity of prototypes
✓ Certification is required to ensure that AM products meet the
same standards as traditional methods
✓ The most significant barrier to AM adoption is the current skills
gap
✓ Post processing and post curing challenges
✓ Low material strength of the developed components
✓ High cost of production and materials
8
Additive vs Subtractive Manufacturing
Additive Subtractive
➢ Part Complexity;
➢ Material;
➢ Speed;
➢ Part Quantity;
➢ Cost.
Steps in AM Process
Source: Gibson, Additive Manufacturing
Evolution
Source: Royal Academy of Engineering
Application of AM techniques
Source: Google images Current and Potential industries for Additive Manufacturing
Future: Home Manufacturing
Customization:
•Bristle hardness
•Colour
•Handle Style and shape
•Etc.
Old
toothbrush
New toothbrush
Home 3D
Printer
Laser scanner to input
personalized data
Difference between various AM techniques?
✓ Techniques used for creating layers;
✓ Techniques of bonding the layers together;
✓ Speed;
✓ Layer thickness;
✓ Range of materials;
✓ Accuracy;
✓ Cost.
Source: https://gfycat.com/gifs/search/additive+manufacturing
Classification of additive Manufacturing
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Vat photopolymerization/Steriolithography
Laser beam traces a cross-section of the part pattern on the
surface of the liquid resin
Platform descends
A resin-filled blade sweeps across the cross section of the
part, re-coating it with fresh material
Immersed in a chemical bath
Stereolithography requires the use of supporting structures
Material Jetting
“Drop on demand method”
The print head is positioned above build
platform
Material is deposited from a nozzle
which moves horizontally across the
build platform
Material layers are then cured or
hardened using ultraviolet (UV) light
Droplets of material solidify and make
up the first layer.
Platform descends
Good accuracy and surface finishes
Binder Jetting
A glue or binder is jetted from an inkjet style print head
Roller spreads a new layer of powder on top of the previous layer
The subsequent layer is then printed and is stitched to the previous
layer by the jetted binder
The remaining loose powder in the bed supports overhanging
structures
Material Extrusion/FDM
Fuse deposition modelling (FDM)
Material is drawn through a nozzle,
where it is heated and is then deposited
layer by layer
First layer is built as nozzle deposits
material where required onto the cross
sectional area.
The following layers are added on top
of previous layers.
Layers are fused together upon
deposition as the material is in a melted
state.
Powder Bed Fusion
Selective laser sintering (SLS)
Selective laser melting (SLM)
Electron beam melting (EBM)
No support structures required.
PROCESS
• A layer, typically 0.1mm thick of material
is spread over the build platform.
• The SLS machine preheats the bulk powder
material in the powder bed
• A laser fuses the first layer
• A new layer of powder is spread.
• Further layers or cross sections are fused
and added.
• The process repeats until the entire model is
created.
Sheet Lamination
Metal sheets are used
Laser beam cuts the contour of each layer
Glue activated by hot rollers
PROCESS
1. The material is positioned in place
on the cutting bed.
2. The material is bonded in place, over
the previous layer, using the
adhesive.
3. The required shape is then cut from
the layer, by laser or knife.
4. The next layer is added.
Directed Energy Deposition
Consists of a nozzle mounted on a multi axis arm
Nozzle can move in multiple directions
Material is melted upon deposition with a laser, electron beam or arc
PROCESS
1. A 4 or 5 axis arm with nozzle moves
around a fixed object.
2. Material is deposited from the nozzle onto
existing surfaces of the object.
3. Material is either provided in wire or
powder form.
4. Material is melted using a laser, electron
beam or plasma arc upon deposition.
5. Further material is added layer by layer
and solidifies, creating or repairing new
material features on the existing object.
Material Classification for AM
✓ Polymers
✓ Metals
✓ Ceramics
✓ Composites
Polymers Metals
a) ABS polymer a) Pure metals: Ti, Ni etc
b) Acrylics b) Alloys: Ti-based, Ni-
c) Cellulose based, Fe-based, Al-
d) Nylon based, Co-based, Cu-
e) Polycarbonate based
f) Thermoplastic polyester
g) Polyethylene
h) Polypropylene
i) Polyvinylchloride
Source: https://gfycat.com/gifs/search/additive+manufacturing
