The document provides a comprehensive overview of additive manufacturing, also known as 3D printing, detailing its history, advantages, disadvantages, working principles, and various materials used. It highlights the process of creating objects layer by layer from 3D model data, and discusses applications across industries like aerospace, automotive, and healthcare. The conclusion emphasizes the transformative potential of additive manufacturing in modern manufacturing, despite existing challenges such as high equipment costs and intellectual property concerns.

1. KUNAL ADHIKARI
ADDITIVE MANUFACTURING/
3d PRINTING

2. Content
 INTRODUCTION
 HISTORY OF ADDITIVE MANUFACTURING
 ADVANTAGE & DISADVANTAGE
 WORKING PRINCIPLE
 WORK METHOD
 MATERIALS
 PROCESS
 TECHNOLOGY & RESEARCH
 USE OF ADDITIVE MANUFACTURING
 LARGE APPLICATION
 CONCLUSION
 REFERENCE

3. Introduction
 WHAT IS IT:
Additive Manufacturing by ASTM (American Society for Testing and Materials ):
“Process of joining materials to make objects from 3D model data,
usually layer upon layer, as opposed to subtractive manufacturing
methodologies, such as traditional machining”
 NAMING:
Rapid Prototyping: This term was used in the beginning of the
professional use of the technology because the main application was
the manufacturing of prototypes, mock ups and sample parts.
 Todays most common terminologies are:
ADDITIVE MANUFACTURING (AM) or 3D PRINTING

4. History of Additive Manufacturing:
 The earliest Additive Manufacturing technologies first became visible
in the late 1980’s, at which time they were called Rapid Prototyping
(RP) technologies. This is because the processes were originally
conceived as a fast and more cost-effective method for creating
prototypes for product development within industry.
 1983 Charles Hull invents Stereolithography (SLA) Charles
‘Chuck’ Hull was the first to develop a technology for creating
solid objects from a CAD/CAM file, inventing the process he
termed ‘stereolithography’ in 1983. SLA works by curing and
solidifying successive layers of liquid photopolymer resin using
an ultraviolet laser. The field that came to be known variously as
'additive manufacturing', 'rapid prototyping' and '3D printing'
was born.

5. Advantages
 Design complexity and freedom:
The advent of 3D printing has seen a proliferation of products (designed in digital environments), which involve levels of
complexity that simply could not be produced physically in any other way. While this advantage has been taken up by designers
and artists to impressive visual effect, it has also made a significant impact on industrial applications, whereby applications are
being developed to materialize complex components that are proving to be both lighter and stronger than their predecessors
 Speed:
You can create complex parts within hours , with limited human resources. Only machine operator is needed for loading the data
and the powder material, start the process and finally for the finishing. During the manufacturing process no operator is needed
 Customisation
3D printing processes allow for mass customisation — the ability to personalize products according to individual needs and
requirements. Even within the same build chamber, the nature of 3D printing means that numerous products can be manufactured
at the same time according to the end-users requirements at no additional process cost.
 Tool-less
For industrial manufacturing, one of the most cost-, time- and labour-intensive stages of the product development process is the
production of the tools. For low to medium volume applications, industrial 3D printing — or additive manufacturing — can
eliminate the need for tool production and, therefore, the costs, lead times and labour associated with it. This is an extremely
attractive proposition, that an increasing number or manufacturers are taking advantage of. Furthermore, because of the
complexity advantages stated above, products and components can be designed specifically to avoid assembly requirements with
intricate geometry and complex features further eliminating the labour and costs associated with assembly processes.

6. Advantages
 Extreme Lightweight design
AM enable weight reduction via topological optimization
 Sustainable / Environmentally Friendly
3D printing is also emerging as an energy-efficient technology that can provide environmental efficiencies
in terms of both the manufacturing process itself, utilising up to 90% of standard materials, and, therefore,
creating less waste, but also throughout an additively manufactured product’s operating life, by way of
lighter and stronger design that imposes a reduced carbon footprint compared with traditionally
manufactured products.
 No storage cost
Since 3D printers can “print” products as and when needed, and does not cost more than mass
manufacturing, no expense on storage of goods is required.
 Increased employment opportunities
Widespread use of 3D printing technology will increase the demand for designers and technicians to operate
3D printers and create blueprints for products.

7. Disadvantages
 Questionable Accuracy
3D printing is primarily a prototyping technology, meaning that parts created via the technology are mainly test parts. As with any viable test part,
the dimensions have to be precise in order for engineers to get an accurate read on whether or not a part is feasible. While 3D printers have made
advances in accuracy in recent years, many of the plastic materials still come with an accuracy disclaimer. For instance, many materials print to
either +/- 0.1 mm in accuracy, meaning there is room for error.
 Support material removal
When production volumes are small, the removal of support material is usually not a big issue. When the volumes are much higher, it becomes an
important consideration. Support material that is physically attached is of most concern.
 Limitations of raw material
At present, 3D printers can work with approximately 100 different raw materials. This is insignificant when compared with the enormous range of
raw materials used in traditional manufacturing. More research is required to devise methods to enable 3D printed products to be more durable and
robust.
 Considerable effort required for application design and for setting process parameters
Complex set of around 180 material, process and other parameters and specific design required to fully profit from the technology
 Material cost:
Today, the cost of most materials for additive systems ( Powder ) is slightly greater than that of those used for traditional manufacturing .
 Material properties:
A limited choice of materials is available. Actually, materials and there properties (e.g., tensile property, tensile strength, yield strength, and fatigue)
have not been fully characterized. Also, in terms of surface quality, even the best RM processes need perhaps secondary machining and polishing to
reach acceptable tolerance and surface finish

8. Disadvantages
 Intellectual property issues
The ease with which replicas can be created using 3D technology raises issues over intellectual
property rights. The availability of blueprints online free of cost may change with for-profit
organizations wanting to generate profits from this new technology.
 Limitations of size
3D printing technology is currently limited by size constraints. Very large objects are still not
feasible when built using 3D printers.
 Cost of printers
The cost of buying a 3D printer still does not make its purchase by the average householder
feasible. Also, different 3D printers are required in order to print different types of objects. Also,
printers that can manufacture in color are costlier than those that print monochrome objects.
 Unchecked production of dangerous items
Liberator, the world’s first 3D printed functional gun, showed how easy it was to produce one’s
own weapons, provided one had access to the design and a 3D printer. Governments will need to
devise ways and means to check this dangerous tendency.

9. How does additive manufacturing work?
 The term “additive manufacturing” references technologies that grow three-dimensional objects one
superfine layer at a time. Each successive layer bonds to the preceding layer of melted or partially
melted material. It is possible to use different substances for layering material, including metal
powder, thermoplastics, ceramics, composites, glass and even edibles like chocolate.
 Objects are digitally defined by computer-aided-design (CAD) software that is used to create .stl files
that essentially "slice" the object into ultra-thin layers. This information guides the path of a nozzle or
print head as it precisely deposits material upon the preceding layer. Or, a laser or electron beam
selectively melts or partially melts in a bed of powdered material. As materials cool or are cured, they
fuse together to form a three-dimensional object.
 The journey from .stl file to 3D object is revolutionizing manufacturing. Gone are the intermediary
steps, like the creation of molds or dies, that cost time and money

10. Additive manufacturing materials
It is possible to use many different materials to create 3D-printed objects. AM technology fabricates jet engine parts from advanced metal alloys,
and it also creates chocolate treats and other food items.
 Thermoplastics
Thermoplastic polymers remain the most popular class of additive manufacturing
materials. Acrylonitrile butadiene styrene (ABS), polylactic acid (PLA) and polycarbonate (PC)
each offer distinct advantages in different applications. Water-soluble polyvinyl alcohol (PVA) is
typically used to create temporary support structures, which are later dissolved away.(ABS,
Nylon (Polyamide), Polycarbonate, PP, Epoxies, Glass filled polyamide, Windform,
Polystyrene, Polyester, Polyphenylesulfone).
 Metals
Many different metals and metal alloys are used in additive manufacturing, from precious metals like gold and silver to strategic metals like
stainless steel and titanium.(Plain Carbon Steel, Tool Steel, Stainless steel, Aluminium, Copper, Titanium, Bronze, Nickel
Alumides).
 Ceramics
A variety of ceramics have also been used in additive manufacturing, including zirconia, alumina and tricalcium phosphate. Also, alternate layers
of powdered glass and adhesive are baked together to create entirely new classes of glass products.
 Biochemicals
Biochemical healthcare applications include the use of hardened material from silicon, calcium phosphate and zinc to support bone structures as
new bone growth occurs. Researchers are also exploring the use of bio-inks fabricated from stem cells to form everything from blood vessels to
bladders and beyond.(Polycaprolactone (PCL), polypropylene-tricalcium phosphate, (PP-TCP), PCL-hydroxyapatite (HA),
polyetheretherketone-hydroxyapatite, (PEEK-HA), tetracalcium phosphate (TTCP), beta – tricalcium phosphate (TCP),
Polymethyl methacrylate).

11. Process
 AM processes are classified into seven categories
 Vat photopolymerization/Steriolithography
• Laser beam traces a cross-section of the part pattern on the surface of the liquid
resin
• SLA's elevator platform descends
• A resin-filled blade sweeps across the cross section of the part, re-coating it with fresh
material
• Immersed in a chemical bath
Stereolithography requires the use of supporting structures
 Material Jetting
• Drop on demand method
• The print head is positioned above build platform
• Material is deposited from a nozzle which moves horizontally across the
build platform
• Material layers are then cured or hardened using ultraviolet (UV) light
• Droplets of material solidify and make up the first layer.
• Platform descends
• Good accuracy and surface finishes

12.  Binder Jetting
• A glue or binder is jetted from an inkjet style print head.
• Roller spreads a new layer of powder on top of the previous
layer.
• The subsequent layer is then printed and is stitched to the
previous layer by the jetted binder.
• The remaining loose powder in the bed supports overhanging
structures.
 Material Extrusion/FDM
• Fuse deposition modelling (FDM)
• Material is drawn through a nozzle, where it is heated
and is then deposited layer by layer
• First layer is built as nozzle deposits material where required
onto the cross-sectional area.
• The following layers are added on top of previous layers.
• Layers are fused together upon deposition as the material is
in a melted state.

13.  Powder Bed Fusion
 1. Selective laser sintering (SLS) 2.Selective laser melting (SLM) 3. Electron beam melting (EBM)
 No support structures required
process
• A layer, typically 0.1mm thick of material is spread over the
build platform.
• The SLS machine preheats the bulk powder material in the powder bed
• A laser fuses the first layer
• A new layer of powder is spread.
• Further layers or cross sections are fused and added.
• The process repeats until the entire model is created.
 Sheet Lamination
• Metal sheets are used
• Laser beam cuts the contour of each layer
• Glue activated by hot rollers

14. Process
• The material is positioned in place on the cutting bed.
• The material is bonded in place, over the previous layer, using the
adhesive.
• The required shape is then cut from the layer, by laser or knife.
• The next layer is added.
 Directed Energy Deposition
 Consists of a nozzle mounted on a multi axis arm
 Nozzle can move in multiple directions
 Material is melted upon deposition with a laser or electron
beam
Proces
• A4 or 5 axis arm with nozzle moves around a fixed object.
• Material is deposited from the nozzle onto existing surfaces of the
• object.
• Material is either provided in wire or powder form.
• Material is melted using a laser, electron
• beam or plasma arc upon deposition.
• Further material is added layer by layer and solidifies, creating or repairing
new
• material features on the existing object.

15. Technology & Research
 Material
Intensive materials research and development is needed
In metallurgy, it takes about 10 years to develop a new alloy, including the determination of various critical properties such as
fatigue strength. This time frame also applies to developing new materials for AM
Even with existing materials, advancements are needed

16.  Design
• Various AM-oriented design tools must be developed
• CAD systems should be re-invented to overcome its limitations
 Modeling, Sensing, Control, and Process Innovation
• Difficult to predict the microstructures and fatigue properties resulting from AM processes
• The sensing of AM processes may require fast in situ measurements of the temperature,
rate, and residual stress
 Characterization and Certification
• Real production environments and practices are much more rigorous
than those for prototyping purposes.
• The existing AM systems are still predominantly based on rapid prototyping machine
architectures

17. Where does people use 3D Printing?
 Manufacturing applications
 Cloud-based additive manufacturing
 Mass customization
 Rapid manufacturing
 Rapid prototyping
 Research
 Food

18. Large Application
Additive manufacturing is already used to produce an impressive array of products -- everything from food creations to jet engine parts.
 Aerospace
AM excels at producing parts with weight-saving, complex geometric designs. Therefore, it is often the perfect solution for creating ight, strong
aerospace parts.
In August 2013, NASA successfully tested an SLM-printed rocket injector during a hot fire test that generated 20,000 pounds of thrust. In 2015,
the FAA cleared the first 3D-printed part for use in a commercial jet engine. CFM's LEAP engine features 19 3D-printed fuel nozzles. At the 2017
Paris Air Show, FAA-certified, Boeing 787 structural parts fabricated from titanium wire were displayed, according to Aviation Week.
 Automotive
CNN reported that the McLaren racing team is using 3D-printed parts in its Formula 1 race cars. A rear wing replacement took about 10 days to
produce instead of five weeks. The team has already produced more than 50 different parts using additive manufacturing. In the auto industry,
AM's rapid prototyping potential garners serious interest as production parts are appearing. For example, aluminum alloys are used to produce
exhaust pipes and pump parts, and polymers are used to produce bumpers.
 Healthcare
At the New York University School of Medicine, a clinical study of 300 patients will evaluate the efficacy of patient-specific, multi-colored kidney
cancer models using additive manufacturing. The study will examine whether such models effectively assist surgeons with pre-operative
assessments and guidance during operations.
Global medical device manufacturing company Stryker are funding a research project in Australia that will use additive manufacturing
technology to create custom, on-demand 3D printed surgical implants for patients suffering from bone cancer.
In general, healthcare applications for additive manufacturing are expanding, particularly as the safety and efficacy of AM-built medical devices
is established. The fabrication of one-of-a-kind synthetic organs also shows promise.
 Product Development
As the potential for AM's design flexibility is realized, once impossible design concepts are now being successfully re-imagined. Additive
manufacturing unleashes the creative potential of designers who can now operate free of the constraints under which they once labored.

19. Overview of the market
 Additive Manufacturing is currently a $2.2 billion industry worldwide.
 Market is triple by 2018 to roughly $6 billion.
 Context: Injection molding market expected to be $252 billion in 2025
 Sales for low cost machines (<$5000) – 35,508 in 2012
 Sales for professional machines (>$5000) – 6,494 in 2011
Global Additive Manufacturing (3D Printing) Market Share, By Industry, 2012 (%)

20. Challenges with 3D Printing
 1. 3D printing isn’t standardized.
 2. Additive manufacturing impacts the
environment.
 3.Equipment and product costs are high.
 4. There’s a 3D printing knowledge gap.
 5. Additive manufacturing complicates
intellectual property.

21. conclusion
 The process of joining materials to make objects from three-
dimensional (3D) model data, usually layer by layer
 Traditional subtractive machining techniques rely on the removal of
material by methods such as cutting or milling
 Has many advantages over traditional manufacturing processes
 Seven processes of AM
 AM is on the verge of shifting from a pure rapid prototyping
technology
 Manufacturing metal components with virtually no geometric
limitations or tools offers new ways to increase product performance or
establish new processes and revenue streams

22. THANK YOU