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 • Distinguished from traditional subtractive machining techniques

1. Additive Manufacturing
Fauzia Iqbal
Assistant Professor
Department of Physics
University of the Punjab, Lahore Pakistan

2. Segment-I
 Introduction and Basic Principles
 Additive manufacturing
 Evolution of printing
 Benefits and developments
 Distinction b/w AM & CNC
Segment-II
 Materials and their Fabrication
 Material selection and processing
 Challenges of selection 2
Segment-III
 Fabrication and Printing technology
 DLP Printing
 Synthesis processes
 Process Parameters
Segment-IV
 Post Processing
 Thermal & non thermal approaches
 Characterization & testing
Segment-V
 Application Areas
 Future directions and scope
Outline

3. 3
1. Additive manufacturing technologies (2nd Edition), I. Gibson, D. Rosen, B. Stucker,
Springer (2015)
2. Additive Manufacturing of Metals: The Technology, Materials, Design and
Production, Li Yang, K. Shu, B. Baughman, D. Godfrey, F. Madina, M. B. Menon, S.
Viener, Springer (2017)
3. 3D Printing: Understanding Additive Manufacturing (2nd Edition), A. Gebhardt, J.
Kessler, L. Thurn, Hanser Publications (2018)
4. Additive Manufacturing: 3D Printing for Prototyping and Manufacturing, A.
Gebhardt, J. S. Hotter, Hanser Publications (2016)
Course Books

4. Contents
Introduction to Manufacturing
Additive Manufacturing
Conventional Manufacturing
 Working steps of AM
Fabrication methods
Competitive Advantages
Printing Technologies
Applications

6. Introduction to Manufacturing
Conventional Manufacturing Additive Manufacturing

7. What is Additive Manufacturing (AM)?
• 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
• Distinguished from traditional subtractive machining techniques

8. Why Additive Manufacturing?
Fast prototyping
Complex geometries
Multiple materials; new
materials
Enhanced performance
Low volume manufacturing
A growing library of
printable materials
Momentum, confidence, and
creative vision

10. Conventional Over Additive Manufacturing
10
Step Stages of both Processes

11. Limitations with Conventional Manufacturing
• Plenty of wastage
• Time Consuming
• Costly custom parts
• Large upfront investment
• Inappropriate for small run
• Needs super expensive molds
• Subtractive manufacturing process
• Limitations in intricate design fabrication
• Object is carved from standard machining processes
such as drilling, cutting, broaching & milling.
• Computerized numerical control (CNC) machine needs precision and
strength

12. Problems with Conventional Machining

13. Working process of AM
1. Create a 3D model using computer-aided design (CAD) software.
2. Convert the 3D model into numerous digital slices or layers.
3. Transfer the 3D model to the 3D printer's computer and load the material.
4. Build the object layer by layer using the selected additive manufacturing process.
5. Remove the object from the build platform and any excess or support material.
6. Finish the object by debinding, curing, polishing, or other post-processing methods.

14. Why Use the Term Additive Manufacturing?
The technology we are referring to is primarily the use of additive processes,
combining materials layer-by-layer. The term Additive Manufacturing, or AM,
seems to describe this quite well, but there are many other terms which are in use.
Automated Fabrication (Autofab)
Freeform Fabrication or Solid Freeform Fabrication
Additive Manufacturing or Layer-based Manufacturing
Stereolithography or 3D Printing
Rapid Prototyping

16. Materials for Additive
manufacturing
& their
Characteristics

17. Materials & their Characteristi
or Type of materials
Materials Characteristics
 Polymers (vinyl, styrene polymers) Biocompatible, low cost, light weight, stability in
oral environment, structurally amorphous, high
transparency, smooth surface, good mechanical
properties & ease of fabrication.
 Metal-based materials (stainless steel alloys,
titanium, Cobalt-based alloys)
Biologically compatible, corrosion & wear
resistant, good mechanical properties, high tensile
and yield strength or fracture toughness.
 Polyesters
polycarbonate (PC), polycaprolactone (PCL)
and polylactic acid (PLA)
mechanically robust, amorphous and transparent
polymers, biodegradable & biocompatible.
 Nanogels (hydrogels) Biocompatible, often biodegradable, soft
materials resembling to living tissues, able to
alter the stability in environment (temperature,
PH).
 Ceramics (Zirconia, Alumina) Common, highly biocompatible, strong
mechanical properties, excellent wear resistance,
superior esthetics, safe & free of toxicity.

18. Material
Extrusion
Sheet
Lamination
Binder
Jetting
Technology
&
Deposition
Methodologies

19. Classification
Different additive manufacturing processes for the production of ceramic
components are
categorized into major areas:
1. Material Extrusion
2. Photopolymerization
3. Material Jetting
4. Sheet Lamination
5. Powder Bed Fusion
6. Direct Energy Deposition
7. Binder Jetting

20. Comparison of Four Generations of SLA
SLA Printing
Speed
System
Resolution
Printable
Size
Light
Source
Laser Scanning
Stereo-lithography
Scanning speed:
hundreds to
thousands of
millimeters per
second
A few microns
(~100 nm for 2PP
system)
From tens to
hundreds of
millimeters
UV light (Fs laser
source for 2PP)
Projection Stereo-
lithography
Tens of millimeters
per hour
A few microns
(typically greater
than 5 microns)
Tens of millimeters UV/Visible light
Continuous Stereo-
lithography
Hundreds of
millimeters per hour
A few microns
(typically greater
than 5 microns)
Tens of millimeters UV/Visible light
Volumetric Stereo-
lithography
Greater than 105
mm3 per hour
80 ~ 300 microns Tens of millimeters UV light
Huang, J., Qin, Q., & Wang, J. (2020). A review of stereolithography: Processes and systems. Processes, 8(9), 1138.

21. Fabrication Steps of 3D Printing
STL
File
Model
Slicing
1st Layer
Deposition
All
Layers
Completed
Yes Advance to
next layers Finished
Remove
the Model
14

22. Application Trends
Biomedical
Automotive
Tool and Mold Making
Aerospace and Defense
Electronics
Consumer Products