2. The first industrial revolution “began
in Britain in the late 18th century, with
the mechanisation of the textile
industry.
Source: http://www.kish.in/the_industrial_revolution/
First Industrial Revolution
3. The “second industrial revolution came in the early 20th century, when Henry
Ford mastered the moving assembly line and ushered in the age of mass
production.” The third revolution “is under way” and that consists of
manufacturing “going digital.”
Second Industrial Revolution
10. What is 3D Printing?
• is a form of Additive Manufacturing
– Process of joining materials to make an object
from 3D model Data; layer-by-layer process
11. What is 3D Printing?
• Digital Fabrication
- it takes a model
└a digital design
└turn into real, physical Object
13. How 3D Printing Can Change the world?
• Medical procedures
• Advances in research
• Product prototyping
• Historic Preservation
• Architectural Engineering Construction
• Advanced Manufacturing
• Food Industries
• Automotive
• Accessories
16. CUTTING
• What is it?
• What does it look like?
• What are its advantages?
• When would it be used?
17. DEFINITION
USES
ADVANTAGES
EXAMPLES
SUMMARY: CUTTING
A process of making products from varying materials
using cutting tools such as laser cutters, vinyl cutters,
razors and water jets.
• Relatively simple to manufacture and operate
• Simple 2D file input
• Quick fabrication
• Can be used with multiple materials
• Low material waste
• Modeling 2D products
• Modeling relatively simple products
18. FUR AND LEATHER CRAFT
Public domain, via WikiMedia Commons
LASER CUTTING
“Laser Cutting Snowflakes” by Andy Dingley, licenced under CC-BY-SA-3.0 via Wikimedia Commons
19. SUBTRACTIVE MANUFACTURING
• What is it?
• What does it look like?
• What are its advantages?
• When would it be used?
"Yellow Green Orange fluorescent marker" by photosteve101 is licensed under CC BY 2.0
20. DEFINITION
USES
ADVANTAGES
SUMMARY: SUBTRACTIVE
MANUFACTURING
A process of making products by removing material
from a solid object
• Traditional, well-known method
• Long history of use
• Relatively simple to manufacture
• Milling bits are relatively low-cost
• Can be used to model strong/thick materials
• Creating 3D models and tooling
• Cutting “2D elements” in stronger or thicker
materials which require a stronger machine
21. FORMING
• What is it?
• What does it look like?
• What are its advantages?
• When would it be used?
"Yellow Green Orange fluorescent marker" by photosteve101 is licensed under CC BY 2.0.
22. DEFINITION
USES
ADVANTAGES
SUMMARY: FORMING
A material deformation process that reshapes a work
piece without reducing or adding material
• Traditional, well-known method
• Long history of use
• Reducing storage space
• Special materials
23. • What is it?
• What does it look like?
• What are its advantages?
• When would it be used?
ADDITIVE MANUFACTURING
"Yellow Green Orange fluorescent marker" by photosteve101 is licensed under CC BY 2.0.
24. DEFINITION
USES
ADVANTAGES
ADDITIVE MANUFACTURING –
SUMMARY
A process for making 3D products by primarily adding
material rather than removing it. It has become
synonymous with 3D printing.
• Low-cost manufacturing
• Multiple materials (PolyJet)
• Real thermoplastics (FDM)
• Design freedom
• Closed systems
• Quick production
• Less waste
• Prototyping and tooling
• Complex designs
• Modeling that requires interlocking parts
28. • Additive manufacturing (AM) definition and
characteristics
• 3D printing technologies overview
• Digital materials
• Determining which 3D printing technology to
use
ADDITIVE MANUFACTURING
29. ADDITIVE MANUFACTURING
DEFINITION
A process for making
a 3D solid object by
adding material.
A process of joining
materials to make
objects from 3D
model data, usually
layer upon layer.*
OR
* The ASTM international committee F42, Wohlers Report 2014
30. ADDITIVE MANUFACTURING
APPLICATION
3D printing
“Fabrication of objects through the deposition of a
material using a print head, nozzle, or other printer
technology. The term is often used synonymously
with additive manufacturing”*
* The ASTM international committee F42, Wohlers Report 2014
31. All three appear with nuance in all 3D printing technologies.
Model is sliced into
horizontal layers so
tool paths can be
generated.
3D PRINTING TECHNOLOGIES
WORKING ASPECTS
Support material is
added to support
overhangs and other
structures.
Density of the
material fill influences
the model’s weight
and strength.
SLICING SUPPORT FILL
32. IN THIS LESSON
• Additive manufacturing (AM) definition and
characteristics
• Different 3D printing technologies overview
• Digital materials
• Which 3D printing technology to use?
36. Process Description
Process description:
A UV laser is curing a liquid photopolymer in a vat. The part is
built by lowering the build platform into the vat.
More details:
Stereolithography machines build parts out of liquid
photopolymer through polymerization activated by a UV laser.
Parts are built on to a build platform inside a vat filled with
the liquid photopolymer. The laser is scanning the surface of
the vat which is solidifying. The build platform is lowered
subsequently into the vat and the part is built layer by layer.
37. COURTESY OF ADDITIVELY LTD
STEREOLITHOGRAPHY
ADVANTAGES
A wide range of material
Very good accuracy, surface finishes and details
Machines with large build volume enable large
parts
38. COURTESY OF ADDITIVELY LTD
STEREOLITHOGRAPHY
DISADVANTAGES
Only works with photopolymers
Mechanical properties of parts are therefore not
stable over time
Materials are expensive
The build process is slow
39. COURTESY OF ADDITIVELY LTD
STEREOLITHOGRAPHY
APPLICATIONS
• Prototypes
• Casting patterns
Painted SLA Trade
Show Figure
42. Process description
Process description:
A plastic filament is melted and extruded through a nozzle.
Parts are built by laying down layer-by-layer.
More details:
The melted material is laid down on the build platform, where
it cools and solidifies. By laying down layer on layer, the part is
built. Fused deposition modeling requires support structures
which anchors the parts on the build platform and supports
overhanging structures. Through the use of a second nozzle,
the support structure can be built in a different material.
Several parts can be produced at the same time as long as
they are all anchored on the platform.
43. COURTESY OF ADDITIVELY LTD
Parts have good mechanical properties and are
durable over time.
Can build fully functional parts in standard
plastics.
Parts can be post-processed
FUSED DEPOSITION MODELING (FDM)
ADVANTAGES
44. COURTESY OF ADDITIVELY LTD
Anisotropy in the z-direction (vertical direction)
Step structure on surfaces
Fine details cannot be realized
DISADVANTAGES
FUSED DEPOSITION MODELING (FDM)
45. COURTESY OF ADDITIVELY LTD
FUSED DEPOSITION MODELING (FDM)
APPLICATIONS
•Prototypes
•Support parts
•Small series parts
49. Process description
Process description:
A thin layer of metal powder is selectively melted by a
laser. The parts are built up layer by layer in the
powder bed.
More details:
A laser melting machine distributes a layer of metal
powder onto a build platform, which is melted by a
laser (or multiple lasers). The build platform will then
be lowered and the next layer of metal powder will be
coated on top.
50. Laser melting requires support structures, which
anchor parts and overhanging structures to the
build platform. This enables the heat transfer away
where the laser is melting the powder. Therefore it
reduces thermal stresses and prevents wrapping.
The build envelope can be filled by several parts
being built in parallel as long as they are all attached
to the build platform.
By repeating the process of coating powder and
melting where needed, the parts are built up layer
by layer in the powder bed.
51. COURTESY OF ADDITIVELY LTD
LASER MELTING (LM, SLM, SLS, DMLS)
ADVANTAGES
Can manufacture parts in standard metals with
high density
A constantly widening set of standard metals is
available
Parts can be further processed
52. COURTESY OF ADDITIVELY LTD
LASER MELTING (LM, SLM, SLS, DMLS)
DISADVANTAGES
The technology is rather slow and expensive
Tolerances and surface finishes are limited
53. LASER MELTING (LM, SLM, SLS, DMLS)
• Prototypes
• Support parts
• Small-series parts
• Tools for injection molds
54. ELECTRON BEAM MELTING (EBM)
Process description
Advantages and disadvantages
Main applications
56. Process description
A thin layer of metal powder is selectively melted by
an electron beam. The parts are built up layer by layer
in the powder bed. Electron beam melting is similar to
laser melting, but working with an electron beam
instead of a laser. The machine distributes a layer of
metal powder onto a build platform, which is melted
by the electron beam. The build platform is then
lowered and the next layer of metal powder will be
coated on top. The process of coating powder and
melting where needed is repeated and the parts are
built up layer by layer in the powder bed.
57. Electron beam melting requires support
structures, which anchor parts and overhanging
structures to the build platform. This enables the
heat transfer away from where the powder is
melted. Therefore, it reduces thermal stresses and
prevents wrapping.
The build envelope can be filled by several parts
which are built in parallel as long as they are all
attached to the build platform. Parts are built
under vacuum.
58. COURTESY OF ADDITIVELY LTD
ELECTRON BEAM MELTING (EBM)
ADVANTAGES
Parts can be manufactured in some standard
metals with high density by electron
beam melting.
Parts in standard metals with high density
(above 99%) and good mechanical properties
Requires less support structure
(compared to LM)
Builds parts faster (compared to LM)
59. COURTESY OF ADDITIVELY LTD
ELECTRON BEAM MELTING (EBM)
DISADVANTAGES
Electron beam is slow, expensive and works with
limited set of metals
Parts usually require quite a lot of post-
processing
Does not achieve equally good surface finishes
to laser melting
60. COURTESY OF ADDITIVELY LTD
ELECTRON BEAM MELTING (EBM)
APPLICATIONS
• Small-series parts
• Prototypes
• Support parts
61. ELECTRON BINDER JETTING (BJ)
Process description
Advantages and disadvantages
Main applications
63. Process description
Inkjet print heads apply a liquid bonding agent onto
thin layers of powder. By gluing the particles
together, the part is built up layer by layer.
A binder jetting machine distributes a layer of
powder onto a build platform. A liquid bonding
agent is applied through inkjet print heads bonding
the particles together. The build platform will be
lowered and the next layer of powder will be laid
out on top. By repeating the process of laying out
powder and bonding, the parts are built up in the
powder bed.
64. Binder jetting does not require any support
structures. The built parts lie in the bed of not
bonded powder. The entire build volume can
therefore be filled with several parts, including
stacking and pyramiding of parts. These are then
all produced together. Binder Jetting works with
almost any material that is available in powder
form.
65. COURTESY OF ADDITIVELY LTD
ELECTRON BINDER JETTING (BJ)
ADVANTAGES
Fast and cheap technology
Wide arrange of material types
Works with almost any material that is available
in powder form
Parts in full color are possible.
66. COURTESY OF ADDITIVELY LTD
ELECTRON BINDER JETTING (BJ)
DISADVANTAGES
Parts coming directly from the machine have
limited mechanical characteristics.
Parts are basically particles glued together
resulting in fragile parts with limited mechanical
properties (if not further processed).
67. COURTESY OF ADDITIVELY LTD
ELECTRON BINDER JETTING (BJ)
APPLICATIONS
• Prototypes
• Green parts
• Casting patterns
• Molds and cores
68. MATERIAL JETTING (MJ, DOD)
Introduction
Process description
Advantages and disadvantages
Main applications
70. Process description
Inkjet print heads are used to jet melted wax
materials onto a build platform. The material cools
and solidifies which allows layers to build on top of
each other.
Material jetting machines utilize inkjet print heads to
jet melted materials, which then cool and solidify. By
adding layer on layer, the part is built. Wax materials
are used with this technology. Material jetting
requires support structures for overhangs, which is
usually built in a different material.
71. COURTESY OF ADDITIVELY LTD
MATERIAL JETTING (MJ, DOD)
ADVANTAGES
Good accuracy
Good surface finish
72. COURTESY OF ADDITIVELY LTD
MATERIAL JETTING (MJ, Drop on Demand)
DISADVANTAGES
Limited number of wax-like materials
Fragile parts
Slow build process
73. COURTESY OF ADDITIVELY LTD
MATERIAL JETTING (MJ, DOD)
APPLICATIONS
• Prototypes
• Casting patterns
• Lost wax casting
(jewelry and dental)
76. Process description
Inkjet print heads are used to jet liquid
photopolymers onto a build platform. The material is
immediately cured by UV lamps and solidified which
allows to build layers on top of each other.
By adding layer on layer, the part is built. Several
materials can be jetted at the same time.
Photopolymer jetting requires support structures for
overhangs, which is usually built in a different
material.
77. When hit with a light source, photoinitiators will
transform light energy into chemical energy, causing
the oligomer (also referred to as “binders”) and
monomer mixture to form three-dimensional
polymer networks. To alter the physical properties of
the material, such as the stiffness or viscosity, the
chemistry might include a variety of oligomers and
monomers, such as epoxies, urethanes and
polyesters.
78. COURTESY OF ADDITIVELY LTD
ADVANTAGES
Multiple materials can be jetted together
allowing multi-material and multi-color parts
Functionally graded materials are possible.
Multi-material and/or multi-color parts
Can achieve good accuracy and surface finishes
PHOTOPOLYMER JETTING (POLYJET)
79. COURTESY OF ADDITIVELY LTD
PHOTOPOLYMER JETTING (POLYJET)
Does not work with standard materials but with
UV-active photopolymers which are not durable
over time (thermoset)
Works with UV-active photopolymers.
Therefore, parts are not durable over time and
have limited mechanical properties
DISADVANTAGES
80. COURTESY OF ADDITIVELY LTD
PHOTOPOLYMER JETTING (POLYJET)
APPLICATIONS
• Prototypes
• Casting patterns
• Tools for injection molding
81. IN THIS LESSON
• Additive manufacturing (AM) definition and
characteristics
• Different 3D printing technologies overview
• Digital materials
• Which 3D printing technology to use?
82. DIGITAL MATERIALS
WHAT ARE THEY?
Engineered materials manufactured from two or
more different constituent materials, according to a
digitally encoded three dimensional phase structure
design (the DM code), and produced by an additive
manufacturing process.
85. IN THIS LESSON
• Additive manufacturing (AM) definition and
characteristics
• Different 3D printing technologies overview
• Digital materials
• Which 3D printing technology to use?
86. COURTESY OF ADDITIVELY LTD
CRITERIA FOR CHOOSING THE 3D TECHNOLOGY
My application
Material
Surface finish
Details
Durability
89. Different Types of FFF/FDM 3D
Printers
• Cartesian-XY-head
• Cartesian-XZ-head
• Delta
• CoreXY
• Polar
• Scara (robot arm)
90. Cartesian-XY-head
• The extruder head moves over the X and Y
axis and the bed over the Z. Z axis movement
on such a 3D printer is very precise and
requires very low accelerations, but the bed
needs to be lightweight in order to maintain
accuracy, which makes it more difficult to add
a fully automatic bed leveling system.
91. Cartesian-XZ-head
• This arrangement differs form Cartesian-XY-
head because it moves the bed over the Y axis
and the extruder head over the X axis and the
Z axis. The biggest benefit of this setup is that
the bed can hold a lot of weight, making it
possible to add a (heavy) fully automatic bed
leveling system.
92. Delta
• They are called Delta because the extruder
head is suspended by three arms in a
triangular configuration. Besides that they
have a circular print bed. The benefit of a
Delta 3D printer is that the moving parts are
lightweight and therefore limit the inertia.
That results in faster printing with greater
accuracy.
93.
94. CoreXY
• The movement on the XY gantry depends on a
combined effect of X and Y motors. CoreXY is a
parallel manipulator system, which means
that the motors on a CoreXY system are
stationary. Parallel manipulator systems give
more rapid acceleration than serial stackup
arrangements like Cartesian-XZ-head.
95.
96.
97. Polar
• Polar 3D printers have a rotating print bed,
plus an extruder head that can move left, right
up and down. A polar 3D printer is energy
efficient because it only needs two stepper
motors in contrary to for instance a Cartesian
arrangement which requires a minimum of
one stepper motor for each axis, so usually at
least four.
98.
99.
100.
101. SCARA
• Selective Compliant Assembly Robot Arm or
Selective Compliant Articulated Robot Arm,
means the robot arm moves along the X-Y
plane and uses an additional actuator to move
along the Z-Axis. Nice fact is that it doesn’t
need bearings nor timing belts.
102.
103. Additive Manufacturing
Short introduction to the technology
Major AM processes based on Hopkinson and Dickens’ classification
AM Processes
Liquid Based
Powder Based
Solid Based
• Stereolithography
• Jetting Systems
• Direct Light Processing
• Selective Laser Sintering
• Three-Dimensional Printing
• Fused Metal Deposite Systems
• Electron Beam Melting
• Selective Laser Melting
• Selective Masking Sintering
• Selective Inhibition Sintering
• Electro photographic Layered
Manufacturing
• High Speed Sintering
• Fused Deposition Modelling
• Sheet Stacking Technologies
104. 3D Printer
• Easy to Use
• Economical to Own ones.
• Can be Operated in a Office, lab, Homes, etc.
• Equipping students with skills for the future
• Affordably Price
• takes digital input from 3D data and creates solid, 3D
parts
• used extensively by designers, engineers and hobbyists
for concept development and product design
• objects such as fittings, crafts, jewellery and many
others.
105. COMMON PRINT MATERIALS
• Polylactic Acid (PLA) is a biodegradable
thermoplastic, made from renewable resources like
corn starch or sugarcane. The main benefit of PLA is
that it’s easy to print.
• Acrylonitrile butadiene styrene (ABS) is an oil-
based thermoplastic, commonly found in (DWV)
pipe systems, automotive trim, protective headgear,
and toys (like Lego!). Objects printed with ABS
boast slightly higher strength, flexibility, and
durability than those made of PLA, at the cost of a
slightly more complicated print process (complete
with nasty fumes!).
106. TOP 3D PRINTER MANUFACTURERS
• 3D Systems – Rock Hill, South Carolina, USA
• Autodesk – San Rafael, California, USA
• Formlabs – Somerville, Massachusetts, USA
• Fusion3 – Greensboro, North Carolina, USA
• HP Inc. - Palo Alto, California, USA
• MakerBot – New York City, New York, USA
• Printrbot – Lincoln, California, USA
• Prusa Research - Czech Republic
• Stratasys – Minneapolis, Minnesota, US
• Ultimaker – Geldermalsen, Netherlands
107.
108.
109. THE FUTURE
In the future,
will additive
manufacturing
include only
layering
technologies?
