Presentation on Additive Manufacturing

1. Additive Manufacturing
SUBMITTED BY
SHUBHAM RAJESH PATIL
(20105133)
M-TECH( SMD),
IIT KANPUR
SUBMITTED TO
DR. J. RAMKUMAR
PROFESSOR,
IIT KANPUR
JUNE 25, 2021

2. Presentation
Overview
 Introduction
 Additive Manufacturing
 Families of Additive Manufacturing
 Comparison of Additive Manufacturing
Methods
 Metal Based Additive Manufacturing
processes
 Suitability of Parts for Additive
Manufacturing
 AM Process Selection
 Typical Post Processing Requirements
 Case Studies – Medical Field
 Applications
2

3. Introduction
3
▪ Evolution of Manufacturing Technology
Image credits: https://markmorley68.com/2015/02/22/the-evolution-of-the-digital-manufacturing-business/?hcb=1
Click to add text
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Manufacturing is the processing of raw materials or parts into finished
goods through the use of tools, human labor, machinery, and chemical
processing.

4. ▪ Increasing Pressure on Manufacturing
Requirements
• Shorter time to market
• Higher performance requirements
• Increased product life, durability
• Reduced weight
• Lower cost
• Higher yield and quality
• Improved energy efficiency
• Less waste, environmentally
friendly
4
Potential benefits from additive manufacturing
• Reduced machining time, energy, & cost
• Reduced material consumption
• Material solutions and combinations not
otherwise possible
• Increased part complexity
Additional challenges
• Increasingly complex part
geometries and systems
• Expanded material options
• Manufacturability concerns
• Slow adoption of new techniques
• Qualification of new processes
Image credits: https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.foundry-planet.com%2Fd%2Fsouth-afrika-pump-manufacturing-industry-under-
pressure%2F&psig=AOvVaw1BLyQzVrfo-ZGqofwNnuKy&ust=1624607056804000&source=images&cd=vfe&ved=0CAsQjhxqFwoTCMiW
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5. Additive Manufacturing
 The process of joining materials to
make objects from three-
dimensional (3D) model data,
usually layer by layer
 Commonly known as “3D printing”
 Manufacturing components with
virtually no geometric limitations
or tools.
 AM uses an additive process
 Design for manufacturing to
manufacturing for design
 Distinguished from traditional
subtractive machining techniques
5
▪ What is additive manufacturing
Image credits: https://bitfab.io/blog/additive-manufacturing/

6.  The system starts with applying a thin layer of the powder material to the
building platform.
 A powerful laser beam then fuses the powder at exactly the points defined by
the computer-generated component design data.
 Platform is then lowered and another layer of powder is applied.
 Once again the material is fused so as to bond with the layer below at the
predefined points.
6
Image credit: Marmik, Dave & Sunasara, Shiraj. (2015). Advanced Manufacturing Technique: 3D Printing. 2. 2393-9877.
▪ Functional Principle :

7. Families of Additive Manufacturing
7
Seven additive manufacturing processes according to ASTM Committee F42 on Additive Manufacturing.
Source:Boeing/ASTM
At a glance

8. Families of Additive Manufacturing
8
Material Jetting
Principle: A process where droplets of wax-like materials are selectively deposited on a build
platform. The material cools and solidifies, allowing layers of materials to be placed on top of
each other. After the build, support structures are either mechanically removed or melted away.
Advantages of Material Jetting
• Material jetting can achieve outstanding accuracy and surface finishes
• Parts are good for use in patterns for casting
Disadvantages of Material Jetting
• Limited number of wax-like materials available
• Parts are fragile because of wax-like materials
• Slow build process
VAT Photo Polymerization
Principle: The process used to cure photopolymer liquid resin in a vat layer by layer, turning
it into hard plastic parts using an ultraviolet (UV) laser. The three most common types of this
technology include Stereolithography, Digital Light Processing (DLP), and Continuous Digital
Light Processing (CDLP).
Advantages of Vat Photo Polymerization
• High level of accuracy and good finish
• Relatively quick process
• Large build areas
Disadvantages of Vat Photo Polymerization
• Relatively expensive
• Lengthily post-processing time and removal from resin
• Limited to photo-resins materials
• Can still be affected by UV light after print
• May require support structures and post-curing for parts to be strong enough for
structural use
Image credits: https://youtu.be/APLW6kWyVd0
Source:Boeing/ASTM

9. Families of Additive Manufacturing
9
Binder Jetting
Principle: The process starts with the powder material
being spread over the build platform using a roller and
the print head deposits the binder on top of the powder
where specified. The build platform lowers to allow for
the next layer, and the process repeats until the item is
complete. Any unbound powder gets removed.
Advantages of Binder Jetting
▪ Ability to make parts with a range of different colors
▪ Uses a range of materials: metal, polymers, and
ceramics
▪ Faster AM process
▪ No warping or shrinking of parts
▪ Less waste by reusing any unused powder
▪ Features a two-material method that allows different
binder-powder combinations
Disadvantages of Binder Jetting
▪ Parts require post-processing which adds significant
time to the overall process
▪ Low part strength, not always suitable for structural
parts
▪ Less accurate then Material Jetting
Image credits: https://youtu.be/APLW6kWyVd0
Source:Boeing/ASTM

10. Families of Additive Manufacturing
10
Direct Energy Deposition
Principle: DED creates 3D objects by melting and depositing either
powder-based or wire-based materials from a focused thermal energy
source, including laser, electron beam, or plasma arc. While the process
can make metal, ceramic, and polymer parts, it is mainly used for metal
parts and in more hybrid manufacturing where the substrate bed is
moveable to create complex shapes. DED is also referred to as laser
metal deposition (LMD), 3D laser cladding, or direct light fabrication
because of the different energy sources uses and final use. Lastly, based
on how the process works, it’s mainly used for repairing or reconditing
existing parts by adding material where needed.
Advantages of DED
▪ Strong and dense parts
▪ Fast build rates
▪ Reduction in material waste
▪ Range of material selection: metal, ceramic, and polymer
▪ Materials are easily changed out
▪ Ability to make parts with custom alloys
▪ Parts built to near net shape
▪ Capability to build larger parts
Disadvantages of DED
▪ Capital cost for systems are high
▪ Parts have lower resolution resulting in poorer surface finish, requiring
secondary processing
▪ Support structures are not usable during the build process
Image credits: https://youtu.be/APLW6kWyVd0
Source:Boeing/ASTM

11. Families of Additive Manufacturing
11
Powder Bed Fusion (PBF)
Principle: PBF has four categories of energy sources, laser fused, electron
beam fused, fused with agent and energy, and thermally fused. The energy
source melts either plastic or metal powder particles, which solidifies and fuses
together in a pattern to make the object. The powder bed fusion process uses
two chambers, the build chamber and powder chamber, and a coating roller. To
create the objects, the coating roller moves and spreads the powder material
across the build chamber to deposit a thin layer of powder. Next, the energy
source melts the deposited top layer of the metal powder base. When that
layer has been scanned and fused, the build platform is incrementally lowered
down, simultaneously the powder chamber is raised by the same, and the
process repeats until the object completed.
Advantages of PBF
• Low cost of machines
• No or minimum support structures needed for the build
• Variety of material selection
• Multiple materials can be used
• Capable of recycling powder
Disadvantages of PBF
• Slow and long print time
• Additional post-processing time
• Weaker structural properties
• Variations of surface texture quality
• Support build plate may be needed to avoid warping
• Speed of the print process can determine if the powder is recyclable
• Thermal distortion, mainly for polymer parts
• Machines use a lot of energy to create parts
Image credits: https://youtu.be/APLW6kWyVd0
Source:Boeing/ASTM

12. Families of Additive Manufacturing
12
Material Extrusion
Principle: The most popular AM process in terms of availability for
general consumer demand and quality, uses a continuous filament of
thermoplastic or composite material to construct 3D parts. The material
in the form of plastic filament fed through an extruding nozzle, where it
heated and then deposited onto the build platform layer by layer.
Advantages of Material Extrusion
• Wide selection of print material
• Easily understandable printing technique
• User-friendly method of print material change
• Low initial and running costs
• Faster print time for small and thin parts
• Printing tolerance of +/- 0.1 (+/- 0.005″)
• No supervision required
• Small equipment size
• Low-temperature process
Disadvantages of Material Extrusion
• Visible layer lines
• Extrusion head in continuous motion or the material bumps up
• Supports may be required
• Weak part strength along Z-axis
• Increased print time with finer resolution and wider areas
• Susceptible to warping and other temperature fluctuation issues
• Toxic print materials
Image credits: https://youtu.be/APLW6kWyVd0
Source:Boeing/ASTM

13. Families of Additive Manufacturing
13
Sheet Lamination
Principle: AM that builds 3D objects by stacking and laminating thin sheets of material through bonding, ultrasonic
welding, or brazing. To create the final shape of the object, laser cutting or CNC machining is used. Of all the AM
technologies, this produces parts with the least additive resolution or amount of detail but provides low cost and
faster manufacturing time for quick prototyping using readily available, low-cost material. It can be categorized into
seven types namely Laminated Object Manufacturing (LOM), Ultrasonic Additive Manufacturing (UAM), Selective
Deposition Lamination (SDL), etc. While the types of sheet lamination differ slightly, the overall principle is the
same. The next layer may or may not be bonded to the previous sheet, depending on the process..
Advantages of sheet lamination
• Relatively low cost
• Larger working area
• Full-color prints
• Integrates as hybrid manufacturing systems
• Ease of material handling
• Ability to layer multiple materials
• No support structures needed
• In some sheet lamination
• Depending on technique type used, the material state remains unchanged
• Faster print time, but does require post-processing
Disadvantages of sheet lamination
• Layer height can’t be changed without changing the sheet thickness
• Finishes can vary depending on the material and could require post-processing
• Limited material options available
• Removal of excess material after the laminating phase can be difficult and time-consuming
• Can generate more waste in comparison to other AM methods
• Hollow parts are challenging to produce in some types of sheet lamination
• Bonding strength is dependent on the laminating technique used
Image credits: https://youtu.be/APLW6kWyVd0
Source:Boeing/ASTM

14. ▪ DMLS, LPB, EBM, powderbed fusion
▪ Potential forwidest variety of geometry
▪ Limited to one material
▪ Low depositionrates (0.05 - 0.5 kg/hour)
▪ Part size limited by dimensions of powder bed
▪ Advantages – Small features,tight tolerance,high
geometric fidelity,fully inert environment
▪ Disadvantages – Stress relief & heat treatment often
required,slow build rates, limited part size
Powder Bed
▪ LENS, laser applied powder(LAP)
▪ Multiple build directions
▪ Multiple material deposition
▪ Moderate depositrates (0.5 – 1 kg/hour)
▪ Advantages – Moderate geometric fidelity, shield gas
environment, cladding/repair/resurfacing
▪ Disadvantages – Moderate feature size, moderate
propertypotential, gravity concerns with build
direction
Laser Powder Injection
Laser Applied Powder
Comparison between AM Methods
14
http://en.w ikipedia.org/wiki/Selective_laser_sintering

15. Comparison between AM Methods
15
▪ High plastic work during deposition
▪ High depositionrates (3 – 15 kg/hour)
▪ Limited to line-of-sightprocessing
▪ Lower geometric fidelity
▪ Advantages – Solid state processing,good
mechanical properties,multi-material,
bonding of dissimilar materials
Cold Spray
Laser/EB Wire Additive
▪ LAW,MIG, EB Wire
▪ High rates (3 – 10 kg/hour)
▪ Low cost feedstock
▪ Low feature tolerance
▪ Moderate propertypotential
Ultrasonic & Laminated Object
▪ UC, UAM, LOM
▪ High build rates
▪ Sheet, strip feedstock
▪ Limited geometry
▪ Solid state
Granular Material Bonding
▪ Powderbed inkjet & binder jetting
▪ 3D printing sand, casting molds/cores
▪ Plaster based printing (PP)
▪ Low material properties,low cost
▪ Sintered metal, polymer, & ceramics
ASM Handbook, Vol.6A, W elding Fundamentals and Processes (2011)
Image credits: Google Images

16. ▪ Conductive ink printing, conformalsurfaces
▪ Potential forwide variety of geometries
▪ Excellent resolution depending ontechnique
▪ Multiple material deposition
▪ Micro cold spray
Direct Write
▪ Thermoplastic-based (neat or filled)
▪ Layer-by-layer deposition
▪ Extrusion & shrinkage limits high resolution
▪ Capable of complexgeometries and low
density cores
▪ Multiple material deposition,limited properties
Fused Deposition
Actuators,
Motors &
MEMS
Sensors & Arrays
▪ SLA, Large Area Mask less Photopolymerization (LAMP)
▪ Ceramics and polymers,UV curing materials
▪ Complexgeometries with good resolution
▪ Restricted material selection,resin is often expensive
Stereolithography
Prototype
parts
Cores
Comparison between AM Methods
16
http://en.wikipedia.org/wiki/Stereolithography
http://en.wikipedia.org/wiki/Fused_deposition_modelling

17. Metal Based AM Comparison
AM technology publicizes less raw material waste
compared to conventional machining
 Cold Spray: Depositionefficiencyand overspray can
vary significantly based on material
 Laser AppliedPowder: Capture rates between40%
and 80%, depending on process conditions
 PowderBed: Un-sintered powderhas potential to be
reclaimed and reused - gives rise to additional
questions of repeatability and quality
 Wire Feed: Captures betterthan 90%,similar with
ultrasonic; oftenrequires postmachining
Common constraints for each AM technique
 PartSize: Powderbeds limited in size, typically less
than 12 inches, while wire feed can
accommodate 10 footlong sections or more
 Build Speed: Powderbeds oftentake many hours
(often more than 24 for large structures), LAP may
take up to 12 hours or more, wire feed less than 6
hours
 MaterialProperties: Melting processesresult in
strength similar to cast, solid state processes(cold
spray & ultrasonic) may be better
17
Deposition
Rate
Feature
Resolution
Laser Powder Bed
Electron Beam Powder Bed
Laser Applied Powder
Wire Feed Techniques
Cold Spray
Ultrasonic Fabrication

18. Suitability of Parts for AM
1. Existing clear business case for using AM
 Many processing steps, intensive machining
 AM saves time, has less raw material waste
2. No existing business case, but redesign could create one
 Current design more expensive with AM
 Redesigned part could be more cost effective using
additive technique
 Consolidation of multi-part assembly into single
component
3. No existing business case, low likelihood that redesign could
impact
 Low cost conventional processing (e.g., stamping)
 Satisfactory performance
 High part volumes required
18
AM makes sense for some, but not all components
Redesign may
improve the
performance
independent
of cost

19. Additive Manufacturing Technique
Selection
Some key considerations
 Size of part
 Geometric tolerance
 Surface finish
 Throughput
 Geometric complexity
 Feature size
 Single- or multi-material
 Mechanical properties
 Microstructure
19
Deposition
Rate
Feature
Resolution
Laser Powder Bed
Electron Beam Powder Bed
Laser Applied Powder
Wire Feed Techniques
Cold Spray
Ultrasonic Fabrication

20. Example for : Powder BED
1. Stress relieving via heat treatment to prevent part distortion
• Due to rapid cooling rates, AM parts often contain large
residual stresses
• Conducted while part remains affixed to build plate
2. Removal of part from build plate, typically via EDM
3. Heat treatment to reach required microstructure and
mechanical properties
• As deposited, AM parts often resemble cast
microstructures
• Directionality is common, with grain structures oriented in
the build direction
• May require HIP to reduce porosity and improve density
• Homogenization and solution treatment to reduce grain
orientation
• Hardening/precipitation/strengthening/quench/temper
heat treatment, as required
4. Finish machining to meet required geometry and tolerances
5. Peening, grit blasting, and tumbling to improve surface finish
6. Inspection for defects/flaws
Often overlooked aspect of AM: Post processing requirements
Typical Post Processing Requirements
20
Mitagation
Image credits: https://www.metal-
am.com/articles/distortion-in-metal-3d-printing-
modelling-and-mitigation/

21. Spinal & CMF case studies
in ceramic
▪ Porous scaffolds for Spine surgery
▪ In vivo testing for bone integration
▪ Validation production by Sirris → Tech transfer
▪ Field: Maxillofacial Surgery in France, production
in Belgium
CASE STUDIES : Medical Field
21
[Sirris ADD] [Sirris ADD]
[Sirris ADD]
Credits: http://www.sirris.be/

22. Project: “In vitro testing models -
arteries”
▪ To gain biomechanical know-how
▪ Virtual prototyping, device testing, virtual design iterations
▪ Diagnostic research
▪ Technologies involved: Connex Eden 500 bi-material
3D inkjet printing
CASE STUDIES : Medical Field
22
Credits: http://www.sirris.be/

23. Surgical Cutting Templates
▪ UCL-St Luc (Belgium)
▪ UCL spin-off: VISYOS
▪ Polyamide cutting patient-custom cutting tools
▪ SLS technology + bio-coating
CASE STUDIES : Medical Field
23
Credits: http://www.sirris.be/
World’s first total mandible implant in Titanium
Source: [UHasselt, Layerwise, Xilloc, Sirris, CamBioceramics, Orbis Medisch Centrum, Xios, KUL]

24. CASE STUDIES : Medical Field
24
Credits: http://www.sirris.be/
The future of bio-manufacturing…not so far away!

25. Applications of additive
manufacturing
The fields of application for Additive Manufacturing
are manifold. Metal AM is increasingly being used to
fabricate end-use products for Aerospace Industry
& Suppliers
 Automotive Industry & Suppliers
 Machinery (e.g. Turbines, Special Machinery)
 Medical implants (Dental, Orthopedic)
 Handling and Robotics
 Lifestyle & Sports (e.g. Jewelry, Biking)
 Custom Parts (e.g. Classic Car Parts,
Surgical Tools)
25
Inage credits: Fabrication of bike frame parts - a joint project of Renishaw
w ith Empire Cycles (Source: Renishaw )
----------------- Thank You ----------------