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additivemanufacturingppt-161015184713.pptx

This document provides an introduction to additive manufacturing (AM), also known as 3D printing. It defines AM as a process of joining materials to make objects from 3D model data layer by layer. The document discusses the functional principles and advantages/disadvantages of AM. It also outlines the main AM processes, present trends in the field, gaps/needs, and recommendations to advance AM technology. Overall, the document serves as a high-level overview of AM, its applications, and opportunities for further development.

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NSHM KNOWLEDGE CAMPUS, DURGAPUR- GOI (College Code: 273) Presented By StudentName: ARKA RAJ SAHA University Roll No.: 27332020003 University Registration No.: 202730132010001 Branch: Robotics Engineering Year: 3rd Semester: 6th Paper Name: 3D PRINTING AND DESIGN Paper Code: PE ROB 602C CA1 Introduction to Additive Manufacturing
2 CONTENTS 1. Introduction 2. What is additive manufacturing?  Functional principle  Advantages & disadvantages  Applications 3. AM Processes 4. Present conditions 5. AM - FutureAspects 6. Gaps & needs 7. Recommendations 8. Conclusion
3 Introduction Manufacturing is a process in which raw materials are transformed into finished goods. Additive Manufacturing • Technology that can make anything. • Eliminates many constraints imposed by conventional manufacturing • Leads to more market opportunities. • Increased applications such as 3D faxing sender scans a 3D object in cross sections and sends out the digital image in layers, and then the recipient receives the layered image and uses an AM machine to fabricate the 3D object.
What isAdditive Manufacturing? 4  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
Functional principle  The system starts by applying a thin layer of the powder material to the building platform.  Apowerful 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. 5
ADVANTAGES 6  Freedom of design  Complexity for free  Potential elimination of tooling  Lightweight design  Elimination of production steps DISADVANTAGES  Slow build rates  High production costs  Considerable effort required for application design  Discontinuous production process  Limited component size.
Applications 7 AM has been used across a diverse array of industries, including;  Automotive  Aerospace  Biomedical Consumer goods and many others
AM processes are classified into seven categories 8 1) V at Photopolymerisation/Steriolithography 2) Material Jetting 3) Binder jetting 4) Material extrusion 5) Powder bed fusion 6) Sheet lamination 7) Directed energy deposition
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 9
Material Jetting 10 • 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
Binder Jetting 11 • Aglue 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 12 • 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.
Powder Bed Fusion 13 • Selective laser sintering (SLS) • Selective laser melting (SLM) • Electron beam melting (EBM) No support structures required PROCESS • Alayer, typically 0.1mm thick of material is spread over the build platform. • The SLS machine preheats the bulk powder material in the powder bed • Alaser fuses the first layer • Anew layer of powder is spread. • Further layers or cross sections are fused and added. • The process repeats until the entire model is created.
SheetLamination 14 • Metal sheets are used • Laser beam cuts the contour of each layer • Glue activated by hot rollers PROCESS 1. The material is positioned in place on the cutting bed. 2. The material is bonded in place, over the previous layer, using the adhesive. 3. The required shape is then cut from the layer, by laser or knife. 4. 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 PROCESS 1. A4 or 5 axis arm with nozzle moves around a fixed object. 2. Material is deposited from the nozzle onto existing surfaces of the object. 3. Material is either provided in wire or powder form. 4. Material is melted using a laser, electron beam or plasma arc upon deposition. 5. Further material is added layer by layer and solidifies, creating or repairing new material features on the existing object. 15
Present Condition & Trends 16 TechnologyAnd Research • The model data, usually in stereolithography (STL) format, is first decomposed into a series of 2D, finitely thick cross sections, which are then fed into anAM machine. • Used directly and indirectly to produce prototype parts • Reduce manufacturing and product costs University–Industry Collaboration and Technology Transfer More and more companies have begun usingAM technology to; • Reduce time-to-market • Increase product quality • Improve product performance • Costs
17 • Metal-based AM processes have recently emerged in industrial applications for manufacturing items such as automotive engines, aircraft assemblies, power tools, and manufacturing tools including jigs, fixtures, and drill guides EducationAnd Training • Educating the general public about AM empowers people to build what they dream. • FormalAM education has already been integrated into curricula at different levels. • Educational materials on rapid prototyping have long been a part of manufacturing engineering courses
AM - Future Aspects 18 TechnologyAnd Research • “ Third industrial revolution “ • The cost effective mass customization of complex products • Reduced material waste and energy consumption • Adapt new product designs without the additional expenses • In the biomedical field,AM can be used to fabricate tissue scaffolds that are biocompatible, biodegradable, and bio-absorbable Education & Training • AM holds great potential for promoting science, technology, engineering, and mathematics (STEM) education • The availability of low-cost 3D printing equipment is creating the opportunity for AM-enabled, hands-on labs in primary, secondary, and postsecondary schools across the nation
Gaps & Needs 19 Technology and Research
20 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 forAM • Even with existing materials, advancements are needed Design • V ariousAM-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 ofAM processes may require fast in situ measurements of the temperature, cooling 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
University–Industry Collaboration and Technology Transfer. 21 • To compete with conventional mass production processes,AM technology must advance significantly in order to drastically reduce the cost of fabrication, improve the performance of fabricated parts • The price of materials for AM would need to drop substantially in order to achieve sufficient return on investment to make AM for mass production a reality
Hype Curve 22
Education & Training 23  While numerousAM education resources and training materials are available, there is still no readily applicable, proven model forAM education and training Taking full advantage ofAM will require; • Educating the current workforce • Recruiting a new generation of students • Developing proper design tools
Recommendations 24 Technology and Research. Materials • Development of new materials forAM processes • Formation and mixing of materials in desired forms and with desired properties Design • Methods and tools for simultaneous multifunctional • Product design andAM process design Modeling • Robust physics-based mathematical models of temperature, stress etc. • Prediction of microstructures and fatigue properties resulting from extreme heating and cooling rates inAM processes Sensing and control • Fast-response sensors for detecting defects and phase transformations • Integrated real time sensing and closed-loop control ofAM processes • The production costs, manufacturing time, and part defects must be reduced drastically in order forAM to become hugely successful.
University–Industry Collaboration and Technology Transfer 25 • Collaborations incentivized by federal funding programs • Increased federal research and development (R&D) support Education and Training Teaching Factory In the teaching factory, students are exposed directly to a manufacturing enterprise where they design products to meet customer needs and manufacture their designed products for the market. Other Training Efforts  Promotion of public awareness  Use of the Internet  Establishment of publicly accessibleAM facilities
CONCLUSION 26 • 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 ofAM • 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
References Base Journal ; Additive Manufacturing: Current State, Future Potential, Gaps and Needs, and Recommendations 27 1. ASTM, 2009, ASTM International Committee F42 on Additive Manufacturing Technologies,ASTM F2792–10 Standard Terminology for Additive Manufacturing Technologies,ASTM, West Conshohocken, PA. 2. Wohlers Associates, Inc., 2013, Wohlers Report 2013: Additive Manufacturing and 3D Printing State of the Industry, Wohlers Associates, Fort Collins, CO. 3. Bourell, D. L., Beaman, J. J., Leu, M. C., and Rosen, D. W., 2009, “ABrief History of Additive Manufacturing and the 2009 Roadmap for Additive Manufacturing: Looking Back and Looking Ahead,” Proceedings of RapidTech 2009: US-TURKEY Workshop on Rapid Technologies, Istanbul, Turkey, Sept. 24–25, pp. 1–8. 4. Google 5. Wikipedia
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