Additive Technology

(CAD, 3D Printing)
Types of Manufacturing
 Definition of 3D Printing or Additive Manufacturing
❑ A 3D object can be defined as, "An object or structure that has three dimensions which
includes width, length, and height.“
❑ 3D printing can be defined as; "Structuring a three-dimensional object in its physical
configuration from its digital form“
❑ 3D printing is also known as additive manufacturing due to the process of layering it
involves. Both terms are used synonymously, digital printing is another term used for this
purpose which you might have heard as well.
❑ Additive manufacturing is the opposite of subtractive manufacturing which was used
widely in the past involving gradual removal of layers from a solid block of any material
either be wood or metal to form a 3D object.
❑ Additive manufacturing as the name indicates is the layer by layer deposition of a
specific material to form a 3D shape or structure.
❑ This technique can be employed in powders be it glass, ceramic, metal and resins in
liquid form.

Figure. Subtractive manufacturing versus Additive manufacturing

Figure. 3D Printer Systems
 What is Additive Manufacturing?

● Additive Manufacturing (AM) is an appropriate name to describe the technologies that

build 3D objects by adding layer-upon-layer of material, whether the material is plastic,
metal, concrete.
● In additive manufacturing (AM), material is applied layer by layer in precise geometric
shapes based on a CAD model. In contrast, conventional manufacturing processes
typically involve milling or otherwise removing material to create an object.
● Additive manufacturing refers to the general manufacturing process - the production of
objects by adding material - under which various production processes such as rapid
prototyping, rapid tooling or mass customization.
● Additive manufacturing offers significant benefits to a wide range of industries, whether
it's the ability for agile product customization, functional integration, or rapid and
cost-effective spare parts procurement.
● Complex shapes and design elements can be easily cured on the materials using
additive manufacturing techniques.
 Additive Manufacturing in Industry 4.0

❑ The latest industrial revolution, Industry 4.0, is encouraging the integration of intelligent
production systems and advanced information technologies. Additive manufacturing (AM)
is considered to be an essential ingredient in this new movement.
❑ Industry 4.0 promotes the integration of smart technologies and production systems
through AM.
❑ Compared to subtractive processes like milling, additive manufacturing generally provides
greater geometric freedoms and utilizes less material in Industry 4.0. In contrast to
forming processes such as injection moulding or composites layup, 3D printing does not
require a mould or other tooling to create a part.
❑ Additive Manufacturing Technology like 3D printers has provided companies with the
ability to rapidly prototype and produce high-performance, customized products. Additive
manufacturing reduces build times and creates a more durable product.
❑ Additionally, additive manufacturing allows developers to incorporate complex designs and
features without increasing cost.
 Additive Manufacturing in Industry 4.0

❑ With Industry 4.0, additive-manufacturing methods will be widely used to produce small batches
of customized products that offer construction advantages, such as complex, lightweight designs.
❑ High-performance, decentralized additive manufacturing systems will reduce transport distances
and stock on hand. The production should be faster and cheaper with the use of additive
manufacturing technologies.
❑ As the needs of customer is changing continuously the challenge of increasing individualization of
products and reducing time to market are faced by many companies.
 Process Involves 3D printing or Additive Manufacturing

❑ A few basic processes that are involved in 3D printing which are: -

1. Modelling: 3D printing begins with the process of designing the product in digital form
using software like AutoCAD(Automated computer aided design), solid works, etc.
 Process Involves 3D printing or Additive Manufacturing
2. STL File Format: STL file format is mostly used in Stereo lithography.
❑ Stereo lithography uses focused UV light to transform liquid photopolymer plastic into solid
form.
❑ It is also called Standard Tessellation Language or Standard Triangle Language.
❑ This format approximates the surfaces of a solid model with triangle.
❑ STL file format is used for describing the surface geometry of an object to be printed by the
3D printer before the process starts.
❑ An STL file stores information about your 3D model.
The format represents the raw surface of a model with
small triangles. The more complex and detailed the
structure is, the more triangles will be used to
represent the model.
❑ Once your model is created, It needs to translate it in a
language of 3D printer will understand. The
information of an STL file is only describing the
geometry of the model, there are no specifications about
the texture, the color or the material of your model. It
has all the information about the surface of the object,
exactly what the 3D printer will print.
 Process Involves 3D printing or Additive Manufacturing
3. 3D Slicing: 3D slicing is the process of breaking down a design into several layers. A slicer
generates a G code(Geometry code) which helps in providing instructions to the 3D printer
that is how the print process should be carried out.
❑ G-code is a language that humans use to tell a machine how to do something. With 3D
printing, g-code contains commands to move parts within the printer. G-code
consists of G- and M-commands
Process Involves 3D printing or Additive Manufacturing
 The basic working principle of additive manufacturing
AM technologies are made up of five basic steps: -

1. The first step is the generation of three-dimensional (3D) geometric modelling of the
components to be made in AutoCAD, Pro/E, Catia, Solid work, or using any other CAD
software.
 The basic working principle of additive manufacturing
AM technologies are made up of five basic steps: -

2. After the creation of the digital CAD model, the second step is the conversion of the CAD file
to the additive manufacturing file (AMF) format [6] or a standard triangle language (STL) file.
These are the standard input file formats accepted by any AM machine. The STL file format is
the representation of the CAD model by a series of triangles.
3. The third step is the slicing process of the STL or AMF files. Before the slicing process is
commenced, the part orientation is optimized for the building process based on various
optimization parameters, which include the ease of building with no or minimal support
structure and minimum building time.
 The basic working principle of additive manufacturing
AM technologies are made up of five basic steps: -

4. Printing order to the 3D Printer

5.The fifth step is the removal of the component from the build platform when the building
process is completed. In this step, the support structures are removed, the part is cleaned up.
Figure. Schematic diagram of the basic principle of additive manufacturing technology
 Advantages of Additive Manufacturing

❑ 3D printing first gained traction as a tool for rapid prototyping, but as the technology
has advanced, there are now numerous advantages to choosing additive
manufacturing for production. Here are some of them:
❑ Design freedom
❑ Material options
❑ Light weighting
❑ Speed
❑ Less waste
❑ Cost savings
❑ On-Demand Production
Application of Additive Manufacturing

Medical Equipment
Hearing aids
Toys And Games
Assembly Parts
Art and Design
Jewellery
Automotive Industry
Architectural Designs
Application of Additive Manufacturing
 Questions
● Differentiate between conventional manufacturing and
additive manufacturing. (10-marks)
● Explain briefly about the role of additive technology in
Industry 4.0. (10-marks)
● List the various processes involved in 3D printing or additive
manufacturing with a schematic diagram, and what are its
advantages and limitations? (10-marks)
 MCQ
● What is the name of the process where a 3D model is created by curing
liquid resin with a light source, typically ultraviolet light?
● a) FDM
b) SLA
c) SLS
d) DLP
● Which of the following is a major advantage of 3D printing?
● a) High production speed
b) Low material cost
c) Customization and prototyping
d) Limited design freedom
 MCQ
● What does the term "additive manufacturing" refer to in 3D printing?
● a) Printing on top of existing material
b) Adding extra layers on top of a printed model
c) The process of building an object layer by layer
d) Reducing material waste
● What does the acronym "STL" stand for in 3D printing?
● a) Stereolithography
b) Standard Template Language
c) Selective Laser Technology
d) Solid Transfer Layer