This presentation gives clear idea about fundamentals of Additive Manufacturing and its engineering applications.

1. Webinar on
Fundamentals of
Additive
Manufacturing
By
Rayappa Shrinivas Mahale
Research Scholar, School of Mechanical
Engineering, REVA University, Bengaluru, India
Email: rayappamahale@gmail.com

2. Agenda
• Introduction
• Additive V/S Subtractive Manufacturing
• History of Additive Manufacturing
• Additive Manufacturing Application Timeline
• Overview of AM Technologies
• Indian 3D Printing Industry – Highlights of the year 2020
• Practical Applications of Additive Manufacturing
• Further Readings

3. Introduction
Three types of fabrication/manufacturing processes
Source: 3dprint.com University of Akron
Definition of AM: As per ASTM F2792 Additive
Manufacturing (AM) is defined as the process of
joining materials to make objects from 3D model
data, usually layer upon layer, as opposed to
subtractive manufacturing methodologies
Fig: Stereolithography
Source: Formlabs
Fig: AM Process Flow
Source: DUPress.com 3

4. Additive V/S Subtractive Manufacturing
Source: 3DE-SHOP 4

5. History of AM
Invention of
Stereolithography
by Charles Hull
(1983)
3D Systems
entered to market
(1987)
Selective Laser
Sintering (SLS) by
DTM CORP (1992)
Direct Metal Laser
Sintering (DMLS) by
EOS (1994)
OPTOMEC sells first
Powder Laser
Deposition System
(1998)
EXTRUDE HONE
introduces metal
BJT (1999)
FOCKELE &
SCHWARZE
introduce first LB –
PBF system (2001)
TRUMPF enters PBF
market (2003)
RENISHAW buys
MTT Technologies
(2011)
HP enters AM
Market (2016)
Open-Source 3D
Printers (2017)
Rise of Industrial
AM (2018)
SLM, MJF Cost
models (2020)
Source: AMPOWER Report 2021
5

6. AM Application Timeline
Rapid Prototyping
(1998-1994)
Rapid Casting
(1994)
Rapid Tooling
(1995)
AM for
Automotive
Applications (2001)
AM Polymers for
Aerospace
Applications (2004)
AM Polymer Jigs
and Guides for
Medical
Applications (2005)
AM Metals for
Medical Implants
(2009)
AM Metals for
Aerospace
Applications (2011)
Nano
Manufacturing
(2013-2016)
Architecture (2013-
2017)
Biomedical
Implants (2013-
2018)
In Situ Bio
Manufacturing
(2013-2022)
Full Body Organs
(2013-2032)
Source: Courtesy of Graham Tromans; Aranca Analysis
6

7. Seven AM Technologies
In order to help standardize additive manufacturing in the United States the ASTM F42 Committee on
Additive Manufacturing Technologies was formed in 2009 and categorized AM technologies into seven
categories
7
Source: Courtesy of Roland Berger

8. Overview of AM Technologies
✓Fused Deposition Modeling (FDM)
✓Stereolithography (SLA)
✓Selective Laser Sintering (SLS)
✓Selective Laser Melting (SLM)
✓Laser Metal Deposition (LMD)
✓Laminated Object Manufacturing (LOM)

9. Fused Deposition Modeling (FDM)
9
Source: CustomPartNet LLC
FDM is a technology where the melt
extrusion method is used to deposit
filaments of thermal plastics according
to a specific pattern
ABS: Acrylonitrile Butadlene Styrene, PC: Polycarbonate, PLC:
Polylactic Acid, PI: Polyimide

10. Stereolithography (SLA)
10
Source: CustomPartNet LLC
The SLA process is based on photo-polymerization of liquid
monomers using UV radiation. A UV laser is scanned over a layer
of the liquid monomer to cure the monomer in selected areas as
dictated by the part geometry. After completion of one layer,
another layer of resin is coated on top of the cured layer and the
process is repeated until the part is completed.

11. Selective Laser Sintering (SLS)
11
Source: http://en.wikipedia.org/wiki/Selective_laser_sintering
SLS uses a high-powered laser beam to join raw
materials and create the desired product. The material
can be plastic, metal, glass or ceramic in a powdered
form. The laser beam takes cross section geometrical
coordinate detail from a CAD drawing and adds the
powder surface accordingly. When the layer is finished,
the surface is powdered again, and the process is
repeated until the model is complete.
PA: Polyamide, PAEK: Polyaryletherketone

12. Selective Laser Melting (SLM)
12
SLM is an AM technique developed to melt and fuse metallic powders
via a high-power density laser. The principle of SLM process starts with a
building platform applied with very thin layers of metallic powders,
which are completely melted by one or several laser beams. The cross-
section area of the designed 3D part is built by selectively melting and
re-solidifying metallic powders in each layer. The building platform is
then lowered by a small distance and a new layer of powder are
deposited and levelled by a re-coater. The powder particles can be
selectively melted according to the CAD design
Source: Xu Song, Feng Li Reference Module in Material Science and
Materials Engineering, 2020

13. Laser Metal Deposition (LMD)
13
LMD is an additive production process that uses a laser beam to
form a pool of metal on the surface of the metallic substrate into
which the metal powder is injected using a gas system. The
absorbed metal powder produces a deposit on the surface. LMD is
replacing many traditional manufacturing processes such as GMAW
and Thermal Spraying.
Source: SPI Lasers Ltd

14. Laminated Object Manufacturing (LOM)
14
In LOM material sheet is unwound from feed roll onto the stack
and bonded to the previous layer using a heated roller. The roller
melts a plastic coating on the bottom side of the paper to create
the bond. The profiles are traced by an optics system that is
mounted to an X-Y stage. During the LOM process layers of plastic
or paper are fused or laminated together using heat and pressure,
and then cut into the desired shape with a computer-controlled
laser.
Source: CustomPartNet LLC

15. Indian 3D Printing Industry – Highlights of the year 2020
✓Hindustan Aeronautics Limited (HAL) and Wipro 3D signed an MOU for Metal 3D Printing Adoption
in Aerospace.
✓Intech Additive Solutions Pvt. Ltd. the Pioneers and Industry experts in Metal Additive
Manufacturing in India, launched a truly ‘Made in India’ range of Metal 3D printers.
✓Surat-based STPL3D 3D Printed World’s Smallest Replica of the “Statue of Unity”.
✓T-Works, India’s largest prototyping centre in Hyderabad, showcased 3D printed UAVs (Unmanned
Aerial Vehicles) at the Wings India 2020 event.
✓Researchers at Gujarat Forensic Sciences University (GFSU), the world’s first and only university
dedicated to forensic and allied sciences, are using 3D scanning and 3D printing technology to
analyze physical forensic data without damaging or contaminating original evidence.
✓In June 2020 HP India and Redington 3D produced 1.2 Lakh 3D Printed Ventilator Parts in 24 Days.
✓In July 2020 Wipro 3D, in collaboration with SCTIMST launched AirBridge, an Emergency Breathing
Assist System.
✓India’s Space-Tech Startup Skyroot Aerospace Unveils 100% 3D Printed Dhawan-1 Cryogenic Rocket
Engine.
15
Source: Manufactur3D Magazine

16. Practical Applications of AM
16
Composites when combined with 3D printing, the
technology can streamline and cut the cost of composite
manufacturing, when compared to typically manual
traditional composite manufacturing methods.
The Emery ONE eBike, developed by Arevo, includes a 3D-printed
composite frame [Image credit: Arevo]
Simulation from the ANSYS Additive Suite soft [Image credit: ANSYS]
creating software solutions to meet AM needs will serve as
a key enabler for integrating the technology into a
production environment.
Manufacturing Execution System (MES) software:
Developed with AM needs in mind, MES software solutions
can help to establish an ecosystem, where different stages
of the AM workflow are linked together to achieve a
streamlined and digitalized AM process management.

17. Practical Applications of AM
17
The advancement of AM within A&D is in large part driven by
key industry players, including GE, Airbus, Boeing, Safran.
These companies and others have identified the value
proposition 3D printing brings to:
•Functional prototypes
•Tooling
•Lightweight components
A few examples of parts that can be produced with 3D printing
include air ducts (SLS), wall panels (FDM) and even structural
metal components (DMLS, EBM, DED).
A 3D-printed injector head for Ariane 6 launcher [Image credit: EOS]
3D printing, particularly with metals, is increasingly
being used in the manufacture of rockets.
An injector head is one of the core elements of a
propulsion module, which forces the fuel mixture
into the combustion chamber.

18. Practical Applications of AM
18
Harris Corp. and Nano Dimension successfully partnered to produce a
3D-printed RF circuit [Image credit: Harris Corp.]
Antennas are an important example of how 3D printing is
speeding up the design process for electronic devices.
3D Printed Custom Seats[Image credit: Porsche]
Porsche has recently introduced a new concept for sports car
seating that leverages 3D printing and lattice design. The new
seats feature polyurethane 3D-printed central seat and
backrest cushion sections, which can be customized by three
firmness levels: hard, medium and soft.
The technology has now evolved to where it can be used to
create functional prototypes using high-performance materials
like ULTEM(Ultra High Molecular Weight Polyethylene) and
PEEK(Polyether Ether Ketone).
“RF” refers to the use of electromagnetic radiation for
transferring information between two circuits that have no
direct electrical connection.

19. Practical Applications of AM
19
3D Printed Heart 3D Printing for Clear Aligners Digital Dentistry
Clear aligners are dental devices used to adjust and straighten
teeth. It is estimated that most of the clear aligners are
currently produced using 3D-printed moulds.
The key technologies enabling this are Stereolithography (SLA)
and Material Jetting, due to their high speed and accuracy. In
addition to these resin-based processes, HP’s powder-based
technology, Multi Jet Fusion, is also gaining traction.
Digital dentistry: the introduction of digital
technologies in dental practice - is transforming the
dental sector. Traditional processes used to create
dental impressions are gradually being replaced by
digital technologies, with desktop 3D printing
systems, 3D scanners and materials becoming more
accessible.
By combining intraoral scanning and 3D printing,
dental labs can create dental products like crowns,
bridges and bite splints, that perfectly match a
patient’s anatomy.
Source: AMFG Autonomous Manufacturing

20. Practical Applications of AM
20
Every day, 3D printing provides patients with affordable custom prostheses,
implants, and devices; it enables doctors to perform their jobs more
effectively with custom tools and models; and it helps medical device
companies develop better products, faster.
The prosthesis-fitting process typically consists of multiple castings and
follow-up appointments to fine tune the fit. For patients, this is often more
than just an inconvenience: having a cast made is uncomfortable.
With 3D printing, patients don’t even need to sit for a physical cast. Instead,
technicians can use a 3D scanner to quickly create a precise 3D model of the
patient’s residual limb. This 3D scan then serves as the basis for an accurate
and affordable 3D printed socket that typically only requires a single fitting
visit.
Heart valves and hearing aids have
traditionally required a full week of
extensive, handmade adjustments by skilled
workers. Prior to 3D printing, producing a
hearing aid took nine steps from casting to
fitting. Now, hearing aids can be 3D scanned
and printed in a single day.
Source: RAPIDMADE, INC.,

21. Practical Applications of AM
21
3D printing provides an affordable and
timely method for producing personalized
surgical tools that are tailored to the needs
of each surgeon and each procedure. Made
with sterilizable and biocompatible plastics
and metals, these tools can be single-use or
reusable. And because these tools can be
produced in such a short time, hospitals
don’t need to keep a large back stock of
instruments and can instead order
production as needed.
Bioprinting works like other
3D printing technologies:
using a range of methods,
material is deposited or
solidified in successive
layers to build 3D objects.
With bioprinting, however,
printers use stem cells or
cells cultivated from tissue
samples. These cells are
held together with a binding
gel or collagen scaffold.
Titanium is the king of biocompatible
metals and is the most popular material
for medical implants. Replacement
joints, pacemakers, cranial plates,
dental implants and more are all
regularly made from titanium. Titanium
is extremely strong, lightweight,
corrosion-resistant and non-reactive. It
can be 3D printed using DMLS, one of
the most expensive 3D printing
technologies.
Source: RAPIDMADE, INC.,

22. Further Readings
https://doi.org/10.1007/s00466-020-01903-4
https://doi.org/10.1108/RPJ-04-2016-0053
fmedina@ewi.org

23. Worlds tallest 3D printed statue of Lord Ganesha was unveiled in
Mumbai at the AMTech Expo 2019
The 3D printed statue was printed on a giant FDM 3D Printer
having a build volume of 1000 cubic feet
The Details of the statue are:
✓ Dimensions (LWH): 5ft × 5ft × 10ft
✓ Weight: 200kg
✓ Build Time: 3 Days
✓ Average Material Deposition Rate: Approx. 3kg per hour
✓ Method: Fused Filament Fabrication (FFF) Layered Deposition
✓ Material: Natural Polyethylene Terephthalate Glycol (PETG)
Pellets
THANK YOU
23
Source: Manufactur3D Magazine