ADDITIVE MANUFACTURING

1. UNIT 3
LIQUID BASED AND SOLID BASED ADDITIVE
MANUFACTURING SYSTEMS

2. CLASSIFICATION OF ADDITIVE
MANUFACTURING SYSTEM
It can categorized into 3 types
• Liquid-Based
• Solid-Based
• Powder-Based

3. Liquid Based System – Stereolithography
Apparatus (SLA)
• Stereolithography (SLA) was founded in 1986 by Charles W Hull
and Raymond S Freed and 1987 first commercial AM process was
developed
• SLA is a additive manufacturing technology for producing models,
prototypes, and patterns.
• The first developed AM technique is SLA .
• There are several models/Products available in SLA
 SLA 250/30A
 SLA 250/50
 SLA 250/50 HR

4. Process Of SLA
• 3D systems stereolithography process creates three-dimensional
plastic objects directly from CAD data.
• The SLA process begins with vat filled with photo-curable liquid
resin and elevator table just below the surface of liquid resin.
• The operator loads 3 dimensional CAD model file into the
system.
• The translator converts CAD data into STL file.
• The control unit slices the model and support into a series of
cross-section from 0.025 mm to 0.5 mm thick.
• The computer controlled optical scanning system directs and
focuses the laser beam
• It solidifies 2 dimensional cross section corresponding to the
slice of surface of photo curable liquid resin to a depth greater
than one layer thickness.

5. Process Of SLA
• The elevator table drops enough to cover the solid polymer with
another layer of liquid resin.
• A leveling wiper moves across the surface to recoat next layer of
resin on the surface.
• The laser then draws next layer.
• The process continues building the part from bottom up until
the system completes the part.
• Finally the part is raised from vat and cleaned the excess
polymer.
• The parameters are used Heat energy, layer thickness and
polymer density.

6. SLA – STEREOLITHOGRAPHY

7. Stereolithography - SLA

8. Process Of SLA
• The Main components of SLA are:
 Control computer
 Control panel
 Laser
 Optical system and
 Process chamber

9. Process Of SLA
The workstation used by SLA system known as 3D LIGHT
YEAR exploits the full power of windows NT operating system and
delivers far richer functionality then UNIX based Maestro system.
Maestro includes following softwares:
(1) 3dverify Module. This module can be accessed to confirm the
integrity and/or provide limited repair to stereolithography (STL)
files before part building without having to return to the original
CAD software. Gaps between triangles, overlapping or redundant
triangles and incorrect normal directions are some examples of the
flaws that can be identified and corrected.
(2)View Module. This module can display the STL files and slice file
(SLI) in graphical form. The viewing function is used for visual
inspection and for the orientation of these files so as to achieve
optimal building.

10. Process Of SLA
(3) MERGE Module. By using MERGE, several SLI files can be merged into
a group which can be used together in future process.
(4) Vista Module. This module is a powerful software tool that
automatically generates support structures for the part files. Support
structures are an integral part to successful part building, as they help to
anchor parts to the platform when the part is free floating or there is an
overhang.
(5) Part Manager Module. This software module is the first stage of
preparing a part for building. It utilizes a spreadsheet format into which
the STL file is loaded and set-up with the appropriate build and recoat
style parameters.
(6) SliceTM Module. This is the second stage of preparing a part for
building. It converts the spreadsheet information from the Part Manager
module to a model of three-dimensional cross sections or layers.
(7)Converge Module. This is the third and last stage of preparing a
part for building. This is the module which creates the final build
files used by the SLA.

11. Principle Of SLA
• The SLA process is based fundamentally on following priniciple:
(1) Parts are built from a photo-curable liquid resin that cures
when exposed to a laser beam (basically, undergoing the
photopolymerization process) which scans across the surface of
the resin. The raw material is Photosensitive thermoset polymers
used in this process.
(2) The building is done layer by layer, each layer being scanned by
the optical scanning system and controlled by an elevation
mechanism which lowers at the completion of each layer.

12. Photopolymers
There are many types of liquid photopolymers – solidified by
exposure to electro-magnetic radiation, including wavelengths in the
gamma rays, X-rays, UV and visible range, or electron-beam (EB)
UV-curable photopolymers are resins
There are a large variety of them and some may contain fillers and
other chemical modifiers to meet specified chemical and mechanical
requirements The process through which photopolymers are cured is
referred to as the photopolymerization process.

13. PHOTOPOLYMERIZATION
• Polymerization is the process of linking small molecules (known
as monomers) into chain-like larger molecules.
• When the chain-like polymers are linked further to one another,
a cross-linked polymer is said to be formed.
• Photopolymerization is polymerization initiated by a
photochemical process whereby the starting point is usually the
induction of energy from the radiation source. It terminates for
recombination.

15. The free-radical photo polymerization process
Photo initiator molecules, Pi, which are mixed with the monomers, M,
are exposed to a UV source of actinic photons, with energy of hν . The
photo initiators absorb some of the photons and are in an excited state.
Some of these are converted into reactive initiator molecules, P•, after
undergoing several complex chemical energy transformation steps.
These molecules then react with a monomer molecule to form a
polymerization initiating molecule, PM•.
This is the chain initiation step.
Once activated, additional monomer molecules go on to react in the
chain propagation step, forming longer molecules, PMMM• until a chain
inhibition process terminates the polymerization reaction.

16. Advantages and Disadvantages
The main advantages of using SLA are:
(1) Round the clock operation. The SLA can be used continuously and
nattended round the clock.
(2) Good user support. The computerized process serves as a good ser
support.
(3) Build volumes. The different SLA machines have build volumes ranging
from small to large to suit the needs of different users.
(4) Good accuracy. The SLA has good accuracy and can thus be used or
many application areas.
(5) Surface finish. The SLA can obtain one of the best surface finishes
amongst RP technologies.

17. (6) Wide range of materials. There is a wide range of materials, from
general-purpose materials to specialty materials for specific
applications.
The main disadvantages of using SLA are:
(1) Requires support structures. Structures that have overhangs and
undercuts must have supports that are designed and fabricated together
with the main structure.
(2) Requires post-processing. Post-processing includes removal of supports
and other unwanted materials, which is tedious, time consuming and can
damage the model.
(3) Requires post-curing. Post-curing may be needed to cure the object
completely and ensure the integrity of the structure.

18. Applications
The SLA technology provide methods for reducing time to market,
lowering product development costs, gaining greater control of their
design process and improving product design.
(1) Models for conceptualization(an elaborated concept), packaging and
presentation.
(2) Prototypes for design, analysis, verify ,functional testing.
(3) Parts for prototype tooling and low volume production tooling.
(4) Investment casting, sand casting and molding.
(5) Tools for fixture and tooling design, and production tooling. It is used
as a tooling for Injection moulding.

19. Solid Based System – Fused Deposition
Modelling (FDM)
• Fused Deposition Modelling (FDM) was founded in early 1990 by
Stratasys.Inc.
• FDM is a additive manufacturing technology for producing
models, prototypes, and patterns.
• There are several models/Products available in FDM
 FDM 3000
 FDM Maxum
 FDM Titan

20. Process of FDM
• In this patented process , a geometric model of a conceptual design is
created on a CAD software which uses IGES or STL formatted files.
• It can then imported into the workstation where it is processed through
the QuickSlice® and SupportWork software.
• Within this software, the CAD file is sliced into horizontal layers after
the part is oriented for the optimum build position, and any necessary
support structures are automatically detected and generated.
• The slice thickness can be set manually to anywhere between 0.172 to
0.356 mm (0.005 to 0.014 in) depending on the needs of the models.
Support structure required when the CAD model having an angle of
below 45 degree.
• The modelling material is in spools — very much like a fishing
line.The filament on the spools is fed into an extrusion head and heated
to a semi-liquid state. Support material is used to support overhanging
sections and undercutting sections.

21. Process Of FDM
• The semi-liquid material is extruded through the head and then
deposited in ultra thin layers from the FDM head, one layer at a time.
• Since the air surrounding the head is maintained at a temperature
below the materials’ melting point, the exiting material quickly
solidifies.
• Moving on the X–Y plane, the head follows the tool path generated by
QuickSlice® or Insight generating the desired layer.When the layer is
completed, the head moves on to create the next layer.
• The horizontal width of the extruded material can vary between 0.250
to 0.965 mm depending on model. Reduce the warpage of processed
parts by printing with raft on, proper bed preparation and using
sticking agent.
• Two modeler materials are dispensed through a dual tip mechanism in
the FDM machine.
• A primary modeler material is used to produce the model geometry
• Secondary material, or release material, is used to produce the support
structures.

22. Fused Deposition Modeling (FDM)
Z-motion
Melting head with
XY-motion
Build material
wire spools:
(a) Part (b) Support
Extrusion nozzles
Part
Support
Foam base
Materials:
ABS, Polycarbonate (PC),
Polyphenylsulfonen (PPSF)

23. Principle Of FDM
• The principle of the FDM is based on surface chemistry, thermal
energy, and layer manufacturing technology.
• The material in filament (spool) form is melted in a specially
designed head, which extrudes on the model.
• As it is extruded, it is cooled and thus solidifies to form the
model.
• The model is built layer by layer, like the other RP systems.
• Parameters which affect performance and functionalities of the
system are material column strength, material flexural modulus,
material viscosity, positioning accuracy, road widths, deposition
speed, volumetric flow rate, tip diameter, envelope
temperature, and part geometry.

24. Advantages of FDM
(1)Fabrication of functional parts: FDM process is able to fabricate
prototypes with materials that are similar to that of the actual molded
product. With ABS, it is able to fabricate fully functional parts that
have 85% of the strength of the actual molded part. This is especially
useful in developing products that require quick prototypes for
functional testing.
(2)Minimal wastage: The FDM process build parts directly by
extruding semi-liquid melt onto the model. Thus only those material
needed to build the part and its support are needed, and material
wastages are kept to a minimum. There is also little need for cleaning
up the model after it has been built.
(3)Ease of support removal.:With the use of Break Away Support
System (BASS) and WaterWorks Soluble Support System, support
structures generated during the FDM building process can be easily
broken off or simply washed away. This makes it very convenient for
users to get to their prototypes very quickly and there is very little or
no post-processing necessary.

25. Advantages of FDM
(4)Ease of material change: Build materials, supplied in spool form
(or cartridge form in the case of the Dimension or Prodigy Plus), are
easy to handle and can be changed readily when the materials in the
system are running low. This keeps the operation of the machine
simple and the maintenance relatively easy.
• Restricted accuracy
• Slow process
• Unpredictable shrinkage
Disadvantages of FDM

26. APPLICATION OF FDM
• FDM can be used in following general application:
(1) Models for conceptualization and presentation. Models
can be marked, sanded, painted and drilled and thus can be
finished to be almost like the actual product.
(2) Prototypes for design, analysis and functional testing. The
system can produce a fully functional prototype in ABS. The
resulting ABS parts have 85% of the strength of the actual
molded part. Thus actual testing can be carried out, especially
with consumer products.
(3) Patterns and masters for tooling. Models can be used as
patterns for investment casting, sand casting and molding.