The document discusses additive manufacturing (AM) at the Manufacturing Technology Centre (MTC). It outlines the MTC's goals of accelerating AM standardization, developing robust AM supply chains, and building confidence in AM. It describes various AM processes like binder jetting, powder bed fusion, and vat photopolymerization. The document also discusses benefits of AM like design freedom, mass customization, and reduced lead times. Finally, it provides examples of using AM for ceramic foundry filters and turbine blade casting cores.

1. AM and the Associated
Value Chain
Dr T. Wasley
Senior Research Engineer
Team Lead – Bind and Sinter AM

2. 2
▪ Deliver a series of ESA AM projects through a
frame contract allowing access to state-of-the-art
AM capabilities
▪ Be a centre for space sector companies to
approach to mature their AM products and
process understanding
▪ Consolidate European leadership on AM for space
ADDITIVE MANUFACTURING AT THE MTC
▪ Accelerate standardisation and close standards
gaps in AM
▪ Create strong global partnerships among AM
developers, users and stakeholders
▪ Support education, training, proficiency testing,
and certification programs
▪ Accelerate the uptake of AM by developing the
technology and systems required to address the
key challenges within the AM value chain by:
▪ Developing a robust AM supply chain
▪ Developing AM process chain technology
▪ Building confidence in AM and improve
uptake by UK PLC
UK National Centre for AM
since 2014
ASTM Centre of
Excellence for AM
since April 2018
European Space Agency (ESA)
AM Benchmarking Centre
since May 2017

3. 3
AM ACROSS THE MTC
AM / NCAM
roadmap
Summary for external
dissemination and coordination
AM Process
Materials
Net Shape
NCM
Fusion
Design for
AM
Simulation
NDT &
Metrology
Informatics
Automation
Within themes – can be more
detailed and followed to deliver
plans. Should align with overall
roadmap.
Capability
development
topic
roadmaps

4. SUPPORT ACROSS ENTIRE PROCESS

5. Design
Materials
AM Process
Post-Processing
Inspection
MTC members supporting the National Centre
AM PROCESS CHAIN MEMBERS

6. AM PROCESS CATEGORIES
There are 7 AM process categories of process according to ASTM F2792 “Standard Terminology for AM Technologies”
No AM process is a one-size
fits all solution!
5
6
7
BINDER JETTING
POWDER BED FUSION (PBF)
DIRECTED ENERGY DEPOSITION
(DED)
1
2
3
4
SHEET LAMINATION
VAT PHOTOPOLYMERISATION
MATERIAL EXTRUSION
MATERIAL JETTING

7. CERAMIC AM TECHNOLOGIES
ASTM Category Materials
Vat Photo-
polymerisation
High viscosity filled
resins/pastes
Binder Jetting Powder, jetting fluid
Material Extrusion
Particle filled paste or
filament
Material Jetting Nanoparticle filled ink
Powder Bed Fusion
Ceramic powder,
ceramic/polymer powder
blends
Vat PhotopolymerisationMaterial Jetting
Binder Jetting
Material Extrusion
Sources: Lithoz GmbH, 3DCeram, Johnson Matthey, XJet 3D, Robocasting

8. BENEFITS - PRODUCT FUNCTION
Design freedom Material freedom
Mass customisation Reduced part count
Ability to design parts with geometric features
that cannot be made any other way; allowing
design freedom to create products with enhanced
functionality such as heat transfer [1].
As AM matures, materials will be specifically
designed for use in these processes, leading to
parts with improved material properties such as
chemical [3] or wear resistance.
As tooling isn’t required for AM parts, each
part can be tailored to its specific use or user.
This can create mass customization, from
bone scaffolds to jewelry [2].
AM can enable complex systems to be
designed and manufactured as one part due
to design freedom, leading to reduced part
counts and assembly costs.
Sources: CeramTech, Lithoz
[1]
[2]
[3]

9. BENEFITS - PRODUCT SUPPLY
Waste reduction Reduced inventory
Lead time reduction Decreased cost
AM builds components layer by layer to
near final geometry resulting in significant
material savings [1].
AM can be used as an ‘on demand’ service,
where parts are produced just ahead of when they
are needed. This negates the need to hold extensive
(and costly) product stocks [3].
As tooling isn’t required, parts can be
manufactured in hours/days. Additionally, rapid
design iterations can be realised without
expensive outlay on tooling [2].
AM can offer significant through-life benefits
over traditional manufacturing processes for a
wide range of products and production volumes.
[2]
Sources: Eagle ESI, Kwambio, Precision Ceramics
[3][1]

10. Ceramic Manufacturing Process Chain
Idea Design
Tooling Design +
Manufacture
Source, Create
and/or Validate
Material
Green Forming
Tooling Iteration
and Re-work
Sintering
Inspection and
Validation
Idea Design
Source, Create
and/or Validate
Material
Parameter
Selection
Production
Green
Processing
De-binding +
Sintering
Inspection and
Validation
Conventional
Additive
▪ The additive process replaces conventional forming techniques
▪ ie. Slip casting, dry pressing, extrusion, injection molding, etc.
▪ Eliminates the need for tooling and associated lead times
▪ Requires similar ancillary processes and expertise
▪ Direct fusion process under development - would remove de-binding and sintering requirement

11. Design
Design is THE critical driver in appropriate and optimal use of Ceramic AM technology. Traditional thinking is
limiting advancement.
Idea Design
Source, Create and/or
Validate Material
Parameter Selection Production Green Processing De-binding + Sintering
Inspection and
Validation
DESIGNER/ENGINEER
Freedom of
ideas
generation
Rapid
iterative
development
capability
Capabilities
and
limitations
understood
Ceramic
FIRST?
Designers/
engineers
become
manufacturers
Evolving
guidelines and
recommendations
Eliminate
sub-
assemblies

12. ▪ Thermal properties of ceramics dictate the need to use bind and sinter techniques for processing.
▪ Provides greater material flexibility as most powdered ceramics can be bound and formed into a green
body irrespective of their varying properties.
▪ Material supply is currently limited to OEMs who develop materials optimised for their platform and
supplied at a premium price.
▪ Similarities in ‘green form’ enable application of decades of expertise in ceramic manufacturing to AM
thermal processing.
Idea Design
Source, Create and/or
Validate Material
Parameter Selection Production Green Processing De-binding + Sintering
Inspection and
Validation
Materials
▪ Commercially available materials:
Alumina, Silica, Zirconia, Silicon nitride, Hydroxyapatite,
Tricalcium phosphate, ATZ
▪ Developmental materials guided by customer demand.

13. Many still suffer from limitations such as repeatability/reproducibility and property uniformity/isotropy, some
of which can be controlled through parameter optimisation and downstream processing.
Idea Design
Source, Create and/or
Validate Material
Parameter Selection Production Green Processing De-binding + Sintering
Inspection and
Validation
AM ‘Forming’ Process
Leading commercialised technologies offer significant trade off in capability…….
Source: Lithoz
Source:
Euroceram
Characteristic
Binder
Jetting
SLA
Material
Jetting
Material
Extrusion
Lrg. build area
High density infiltration
Gd Surface Fin.
High resolution hybrid process
Scalable
Mat. Flexibility
Multi-material print heads print heads
Source: XJet 3D

14. *densified + sintered sample damaged during removal of experimental CIP tool
Post Processing
Current process limitations are also leading to increasing
reliance on post-build processing techniques including:
▪ Cold isostatic pressing
▪ Surface treatment/finishing
▪ Infiltration techniques
Green Sintered Densified +
sintered*
Idea Design
Source, Create and/or
Validate Material
Parameter Selection Production Green Processing De-binding + Sintering
Inspection and
Validation
In addition the post-build de-bind and sintering is the most
influential stage in the process chain :
▪ Burns off the polymer binder
▪ Results in ~20% shrinkage of the green part
▪ Sinters ceramic particles and densifies body
Source: Formlabs

15. ▪ AM process introduces 1000’s of defect locations
through layer wise process that need to be understood
and documented to provide solutions.
▪ Individual nature of AM processes dictates potential
need to inspect every part making NDT processes vital.
▪ Develop suitable test methodologies for AM Ceramics.
▪ Can testing standards for conventional ceramics be
applied to those produced via AM?
▪ Would the introduction of process standards provide
justification for more common use?
▪ Work with standards organisations to create both
process and material standards suitable for highly
regulated industries.
Idea Design
Source, Create and/or
Validate Material
Parameter Selection Production Green Processing De-binding + Sintering
Inspection and
Validation
Inspection and Validation
Source: Vidisco
Source: GOM
Source: Manufacturing News

16. CASE STUDY
Ceramic AM of Foundry Filters
Challenge
• Identify suitable build materials for filter processing.
• Optimise process parameters for green strength and
resolution of filter geometries.
• Through customer feedback, ensure filter suitability
for downstream carbonisation and firing processes.
• Solve issues associated with low green strength
through powder and parameter development.
Outcome
• Process parameters and material identified.
• 10 off demonstration filters fabricated for
testing of downstream processes.
• Further filter geometries identified for
testing.
Geometries used to filter and alter the flow characteristics of molten metals being poured at 1650°C in order to reduce
oxidation during pouring and increase throughput.
Re-design and print Carbonization and firing
Full design to production process flow currently
being implemented
Before
pour
After
pour

17. CASE STUDY
Additive Manufacturing of Turbine Blade Casting Cores
Challenge
• Select AM process capable of producing
acceptable part properties.
• Optimise process parameters for green and fired
component characteristics.
• Understand affect of AM process and firing cycle
on dimensional changes.
• Contribute to development of a material suitable
for AM processing.
MTC’s Solution
• Down selection of most suitable AM process.
• Focus on parameters associated with green binding
mechanism to drive mechanical improvement.
• Characterise material behaviour through entire
manufacturing process chain.
Outcome
• Process and machine selected.
• Process parameters identified.
• Crack free fired core geometries produced.
• Additive cores used to successfully cast turbine blades.
[1]
[2]
Casting cores are used to create complex cooling
geometries in turbine blades. Blades are cast containing
ceramic cores before they are chemically removed.
Sources: The Engineer, Morgan Technical Ceramics

18. Contact
Dr Tom Wasley CEng MIMechE
tom.wasley@the-mtc.org
Tel: 02476701524
Mob: 07973732284