This document provides an overview of 3D printing and tooling. It begins by stating the educational objectives and outcomes of the course, which are to understand the principles, methods, materials, possibilities, limitations and environmental effects of additive manufacturing technologies. The document then covers the different units that will be taught, with the first unit providing an introduction to additive manufacturing. It discusses the history and need for additive manufacturing, provides a classification of the different technologies, and discusses how additive manufacturing is used in product development. It also introduces the different materials that can be used for additive manufacturing. In closing, the document emphasizes that additive manufacturing enables both a design and industrial revolution across many industries such as aerospace, energy, automotive

1. 3D PRINTING AND
TOOLING
Presented by
Prof.S.Sathishkumar
Assistant Professor
Department of Mechanical Engineering
Vel Tech Rangarajan Dr.Sagunthala R&D Institute of Science and Technology
Avadi- Chennai-600062

2. Course Educational Objective
undergoing this course we are expected to
• Know the principles, methods, areas of usage, possibilities and limitations as well as environmental effects of the additive
manufacturing technologies
• Be familiar with the characteristics of various materials that are used in additive manufacturing.

3. Course Outcomes
 Describe the differences and of the application of a range of additive manufacturing processes
 Select and use correct CAD formats in the manufacture of a 3D printed part.
 Understand the operating principles, capabilities, and limitations of liquid and solid based additive manufacturing system, including
fused deposition modelling and stereolithography.
 Appreciate the operating principles, capabilities and limitations of powder based additive manufacturing system, including 3D printing
and laser sintering.
 Describe the important process parameters for bio-manufacturing and determine the suitable additive technique for bio-manufacturing.

4. UNIT I-INTRODUCTION
Overview – History – Need-Classification –Additive manufacturing
Technology in product development–Additive manufacturing -
Materials for Additive Manufacturing.

5. INTRODUCTION
Additive manufacturing, also known as 3D printing, rapid prototyping or freeform
fabrication, is ‘the process of joining materials to make objects from 3D model data,
usually layer upon layer, as opposed to subtractive manufacturing methodologies’
such as machining.
 It became a suitable process to produce complex metal net shape parts, and not
only Prototypes.
Additive manufacturing now enables both a design and industrial revolution, in
various industrial sectors such as aerospace, energy, automotive, medical, tooling and
consumer goods.

6. INTRODUCTION

7. Generic AM Process

8. NEED (OR) BENEFITS OF AM
• Increased design freedom versus conventional casting and machining
• Light weight structures, made possible either by the use of lattice design or by designing parts where material
is only where it needs to be, without other constraints
• New functions such as complex internal channels or several parts built in one Net shape process meaning less
raw material consumption, up to 25 times less versus machining , important in the case of expensive or
difficult to machine alloys. The net shape capability helps creating complex parts in one step only thus
reducing the number of assembly operations such as welding, brazing.

9. • No tools needed, unlike other conventional metallurgy processes which require molds and metal forming or
removal tools
• Short production cycle time: complex parts can be produced layer by layer in a few hours in additive
machines. The total cycle time including post processing usually amounts to a few days or weeks and it is
usually much shorter than conventional metallurgy processes which often require production cycles of several
months. The process is recommended for the production of parts in small series

10. Classification of AM Process

11. Materials used for Additive Manufacturing
AM technology was originally developed around polymeric materials, waxes, and paper laminates.
Subsequently, there has been introduction of composites, metals, and ceramics.
CNC machining can be used for soft materials, like medium-density fiberboard (MDF), machinable foams,
machinable waxes, and even some polymers. However, use of CNC to shape softer materials is focused on
preparing these parts for use in a multistage process like casting. When using CNC machining to make final
products, it works particularly well for hard, relatively brittle materials like steels and other metal alloys to
produce high accuracy parts with well-defined properties.

12. THANK YOU