Introduction Applications General principle

1. Additive Manufacturing
P. Bharath Sreevatsava
Roll No.: 165142
B.Tech IV year
MMED
NIT Warangal
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Contents
1. Introduction
2. Manufacturing Processes
3. Manufacturing technologies
4. Manufacturing materials
5. Applications
6. General Principles
7. Advantages and disadvantages

3. What is Additive Manufacturing
Definition:
“Additive Manufacturing— Defined by ASTM International (ASTM 2792-12):
Additive Manufacturing is a process of joining materials to make objects from three
dimensional model data, usually layer upon layer, as opposed to subtractive
manufacturing methodologies.”
(Source: Edgy Labs Website) 3

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Additive manufacturing processes
Material Extrusion
Directed Energy Deposition
Material Jetting
Binder Jetting
Sheet Lamination
Vat Polymerization
Powder Bed Fusion

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Additive manufacturing technologies
Sintering
Direct Metal Laser Sintering (DMLS)
Direct Metal Laser Melting
(DMLM) and Electron Beam Melting (EBM)
Stereolithography (SLA)
Direct Metal Laser Sintering (DMLS)

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Additive manufacturing materials
Thermoplastics
Metals
Ceramics
Biochemicals

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Additive manufacturing applications
Aerospace
Automotive
Healthcare
Product Development

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General Principles

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General Principles
 Modelling
3D printable models can be created with the help of CAD design packages or via 3D scanner.
The most popular are Shape ways, Thing verse, My Mini Factory, and Threading.

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General Principles
 Printing
Before printing a 3D model from .STL file, it must be processed by a piece of software called a "slicer" which converts
the 3D model into a series of thin layers and produces a G-code file from .STL file containing instructions to a printer.
(Cura open source software)

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Functional Principle
The system starts by applying a thin layer of the powder material to the building
platform.
A powerful 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 it at the
predefined points.

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General Principles
 Finishing
Although the printer-produced resolution is sufficient for many applications, printing a slightly oversized version of
the object in standard resolution and then removing material with a higher-resolution process can achieve greater
precision.

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Understanding Additive manufacturing

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Advantages of manufacturing applications
 Time savings
 Weight savings Complex geometries

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 Variety is free: If a part needs to be changed, the change can simply be made on the original CAD
file, and the new product can be printed right away.
 No assembly required: Moving parts such as hinges and bicycle chains can be printed in metal
directly into the product, which can significantly reduce the part numbers.
 Little-skill manufacturing: While complicated parts with specific parameters and high-tech
applications ought to be left to the professionals, even children in elementary school have created
their own figures using 3-D printing processes.
 Less waste: Because only the material that is needed is used, there is very little (if any) material
wasted.
 Infinite shades of materials: Engineers can program parts to have specific colors in their CAD files,
and printers can use materials of any color to print them.
Advantages of manufacturing applications

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Disadvantages of manufacturing applications
 Slow build rates: Many printers lay down material at a speed of one to five cubic inches per hour.
Depending on the part needed, other manufacturing processes may be significantly faster.
 High production costs: Sometimes, parts can be made faster using techniques other than additive
manufacturing, so the extra time can lead to higher costs. Additionally, high-quality additive
manufacturing machines can cost anywhere from $300,000 to $1.5 million, and materials can cost
$100 to $150 per pound (according to compositesmanufacturingmagazine.com).
 Considerable effort in application design and setting process parameters: Extensive knowledge of
material design and the additive manufacturing machine itself is required to make quality parts.

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Disadvantages of manufacturing applications
 Requires post-processing: The surface finish and dimensional accuracy may be lower quality than
other manufacturing methods.
 Discontinuous production process: Parts can only be printed one at a time, preventing economics of
scale.
 Limited component size/small build volume: In most cases, polymer products are about 1 cubic yard
in size, while metal parts may only be one cubic foot. While larger machines are available, they will
come at a cost.
 Poor mechanical properties: Layering and multiple interfaces can cause defects in the product.

18. References:
[1] Vinod G. Gokhare, Dr. D. N. Raut, Dr. D. K. Shinde, ” A Review paper on 3D-Printing Aspects and
Various Processes Used in the 3D-Printing”, International Journal of Engineering Research &
Technology (IJERT) Vol. 6 Issue 06, June – 2017.
[2] Aman Sharma, Harish Garg, ”Utility and challenges of 3 D Printing“, IOSR Journal of Mechanical and
Civil Engineering (IOSR-JMCE) Special Issue - AETM’16 , pp. 49-53, 2016.
[3] NPTEL Additive Manufacturing lectures.
[4] General Electric Additive website : https://www.ge.com/additive/additive-manufacturing

19. Any questions?
Thanks!