Introduction of Additive Manufacturing 1

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ADDITIVE
MANUFACTURING
INTRODUCTION

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Mr. Kiran Wakchaure
Basic Concept of Additive Manufacturing
Session Content
SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON
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Able to understand and apply basic concept of Additive
Manufacturing in real life application
Session Outcome
ADDITIVE Manufacturing

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Mr. Kiran Wakchaure SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON
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Course Content

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Mr. Kiran Wakchaure SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON
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Course Outcomes
CO. No.
COURSE OUTCOME (S)
BLOOM’S TAXONOMY
Level Descriptor
1 Understand the principles and significance of additive manufacturing processes in prototyping
and functional part fabrication.
2 Understand
2 Differentiate between additive manufacturing methods based on materials, energy sources,
costs, and limitations.
3 Apply
3 Study effects of process parameters on (mechanical characterization of 3D printed parts)
material consolidation and solidification rates in FDM, SLS, and 3D printing technologies.
3 Apply
4 Design a 3D part and demonstrate proficiency in using slicing, part orientation, and support
generation for additive manufacturing of complex geometries.
3 Apply
5 Apply heat treatment and micro-finishing methods to improve mechanical properties and
surface finish of additively manufactured components.
3 Apply
6 Apply the knowledge of Additive Manufacturing to precisely manufacture the given
component
3 Precision (Dave’s)
7 Adoption of industry standards and academic integrity for report preparation. 4 Adopt
(Krathwohn’s)

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Mr. Kiran Wakchaure
Textbooks:
1. Gibson, I., Rosen, D.W. and Stucker, B., “Additive Manufacturing Methodologies: Rapid Prototyping to Direct Digital
Manufacturing”, Springer, 2010.
2. Chua, C.K., Leong K.F. and Lim C.S., “Rapid prototyping: Principles and applications”, second edition, World Scientific
Publishers, 2010.
3. Liou, L.W. and Liou, F.W., “Rapid Prototyping and Engineering applications: A toolbox for prototype development”, CRC
Press, 2011.
4. Kamrani, A.K. and Nasr, E.A., “Rapid Prototyping: Theory and practice”, Springer, 2006.
Reference Books:
1. Hilton, P.D. and Jacobs, P.F., “Rapid Tooling: Technologies and Industrial Applications”, CRC press,
2. D.T. Pham, S.S. Dimov, Rapid Manufacturing: The Technologies and Applications of
Rapid Prototyping and Rapid Tooling, Springer 2001.
1. Groover Mikell P, Fundamentals of Modern Manufacturing; 2nd Ed., 2004, 670 Gro-04
2. Milewski, J.O., 2017. Additive manufacturing of metals. Cham: Springer International Publishing.
3. Leach, R. and Carmignato, S. eds., 2020. Precision Metal Additive Manufacturing. CRC Press.
References
SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON
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Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON
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Introduction
ADDITIVE
MANUFACTURING

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Need of Additive Manufacturing

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Additive Manufacturing (AM) refers to a process by which
digital 3D design data is used to build up a component in layers
by depositing material.
(from the International Committee F42 for Additive
Manufacturing Technologies, ASTM)..
What You See Is What You Build (WYSIWYB) Process
Difference between Rapid Prototyping and Additive Manufacturing?
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Additive Manufacturing- Definition

 Part Complexity;
 Material;
 Speed;
 Part Quantity;
 Cost.
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Additive vs Subtractive Manufacturing

 Part Complexity;
 Material;
 Speed;
 Part Quantity;
 Cost.
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Figure: Features that represent problems using CNC machining.
Source: Gibson, Additive Manufacturing
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Source: Gibson, Additive Manufacturing
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Generic AMProcess

STL uses triangles to describe the surfaces to be built. Each triangle is described as three
points and a facet normal vector indicating the outward side of the triangle, in a manner
similar to the following:
facet normal 4.470293E02 7.003503E01 7.123981E-01
outer loop
vertex 2.812284E+00 2.298693E+01 0.000000E+00
vertex 2.812284E+00 2.296699E+01 1.960784E02
vertex 3.124760E+00 2.296699E+01 0.000000E+00
endloop endfacet
Source: Gibson,Additive Manufacturing
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CAD Model into STL Format

Effects of building using different layer thicknesses
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Generic AMProcess

1. Reverse engineering technology
2. Computer aided engineering (CAE):
3D CAD model + Engineering analysis software packages
3. Haptic-based CAD
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Other Related Technologies

 Techniques used for creating layers;
 Techniques of bonding the layers together;
 Speed;
 Layer thickness;
 Range of materials;
 Accuracy;
 Cost.
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Difference between various AM techniques?

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Evolution

Source: Royal Academy of Engineering
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Evolution

Source
Google images
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Current and Potential industries for Additive Manufacturing

Source: SAVING project/Crucible Industrial Design Ltd.; Roland Berger
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Benefits

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Benefits
Source: Roland Berger

Benefits
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Source: Roland Berger

Old toothbrush
New toothbrush
Customization:
•Bristle hardness
•Colour
•Handle Style and shape
•Etc.
Home 3D Printer
Laser scanner to input
personalized data
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Future: Home Manufacturing

Source: Royal Academy of Engineering
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Case Studies

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Prototype
A prototype is an important and vital part of the product development process. In any
design practice, the word “prototype” is often not far from the things that the
designers will be involved in.
An approximation of a product (or system) or its components in
some form for a definite purpose in its implementation.

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Prototype
• Concept of the prototype being physical.
• It covers all kinds of prototypes used in the product
development process, including objects like mathematical
models, pencil sketches, foam models, and of course the
functional physical approximation of the product. Prototyping is
the process of realizing these prototypes.
• the process can range from just an execution of a computer
program to the actual building of a functional prototype.

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Significance of prototypes
The significance of prototypes in the product development process.
Roles of Prototypes:
• Experimentation and Learning
• Testing and Proofing
• Communication and Interaction
• Synthesis and Integration
• Scheduling and Markers
• Example 1: Elbow-Support Design
Description: Physical prototypes used to understand the "feel" of
elbow support in an office chair.
• Example 2: Folding Reading Glasses
Description: Rough physical prototypes for testing and proving
folding mechanism concepts.
• Example 3: Cellular Phone Design
Description: Physical prototype presented to customers for
interaction and feedback.
• Example 4: Comprehensive PDA Prototype
Description: Functional prototype used to integrate components
and address manufacturing issues.
• Example 5: Development Schedule
Description: Prototypes used as markers to enforce the
development schedule.

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Distinction Between AM and CNC Machining
Introduction: Highlighting the differences between AM and CNC machining technologies.
Comparison Points:
Process Overview
AM: Additive process, building layer by layer.
CNC: Subtractive process, material removal from a solid block.
Material Compatibility
AM: Developed for polymers, metals, ceramics, and composites.
CNC: Used for hard materials like metals, steels, and some polymers.
Speed and Process Complexity
AM: Can produce parts in a single stage, relatively faster.
CNC: Requires setup, complex geometries take longer.
Geometric Complexity
AM: Advantageous for complex geometries and internal features.
CNC: Struggles with intricate geometries, accessibility constraints.
Examples:
AM: Creating intricate structures like parts inside a bottle.
CNC: Machining complex geometries may require component assembly.

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Factors Impacting AM and CNC Machining
Introduction: Exploring key factors that affect AM and CNC machining processes.
Factors:
Accuracy and Resolution
AM: Operates with a resolution of tens of microns.
CNC: Accuracy determined by positioning resolution and tool diameter.
Geometry Handling
AM: Builds using 2D cross-sections, suitable for intricate shapes.
CNC: Requires complex 3D programming for surfaces.
Programming Complexity
AM: Minimal programming complexity.
CNC: Involves detailed tool selection, speed settings, and angles.
Implications:
AM: Fine details may depend on material properties and geometry.
CNC: Incorrect programming could lead to machine damage and safety risks.
Conclusion: Consideration of accuracy, geometry, and programming in choosing between AM and CNC.

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Reverse Engineering
Reverse Engineering Technology
Introduction: Exploring the process and advancements of reverse engineering (RE) in 3D
imaging.
Reverse Engineering (RE) Process:
Definition: Capturing geometric data from an existing object.
Data Format: Initially presented as a "point cloud," unconnected points representing object
surfaces.
Connecting Points: RE software like Geomagic used to connect points, fill holes, and
smooth surfaces.
Completeness Challenge: Some areas may not be scanned due to fixtures or obstructions,
leading to an incomplete representation.

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Advancements in Scanning Technology:
Handphone Scanning: Adapted smartphones with built-in cameras can produce high-quality
3D scans at a fraction of previous costs.
Laser Scanning and CT: Objects scanned using laser-scanning, touch-probe technology, or
Computerized Tomography (CT) for complex internal features.
Capture Geometry Inside: Utilizing 2D imaging to capture cross-sections during layer-by-
layer machining, for specific applications.
Applications of RE Data:
3D Facsimile: AM used to reproduce scanned objects, creating 3D replicas.
Complex Artifact Creation: RE data modified, combined with other data to create complex,
freeform objects.
Example: Customized medical implants combining patient data and engineering design.
Conclusion: RE technology enhances product development through data capture,
modification, and application.
Reverse Engineering

The primary input for AM is CAD file/model. Suppose that
for a part (to be copied, modified or repaired)
 CAD was not used in the original design;
there is inadequate documentation on the original design;
the original CAD model is not sufficient to support modification or
manufacturing using modern methods;
the original supplier is unable or unwilling to provide additional parts.
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Introduction to Reverse Engineering

“Examining competitive or similar or prior products in great detail
by dissecting them or literally taking them apart.”
- Dym & Little
Technological principles of a device through analysis of its
structure, function and operation.
“What does this do?” “How
does it do that?”
“Why would you want to do that?”
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Reverse Engineering
Purposes solved
 Dissection and analysis
Experience and knowledge for an individual’s personal
database
 Competitive benchmarking
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Reverse Engineering Process
1. Digitizing the parts
This step uses a reverse engineering device to collect rawgeometry of the object. The data is usually
in the form of coordinate points of the object relative to a local coordinate system.
2. Building CAD models
This step converts the raw point data obtained from step 1 into a usable format.
Physical part CAD model Prototype part
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ISO Standard for Additive Manufacturing
• ISO (the International Organization for Standardization) is a worldwide federation of national
standards bodies (ISO member bodies).
• The work of preparing International Standards is normally carried out through ISO technical
committees. Each member body interested in a subject for which a technical committee has been
established has the right to be represented on that committee. International organizations,
governmental and non-governmental, in liaison with ISO, also take part in the work.
• ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
ISO/ASTM 52900:2021(en) Additive manufacturing — General principles — Fundamentals and vocabulary
https://www.iso.org/obp/ui/#iso:std:iso-astm:52900:ed-2:v1:en
This document was prepared by ISO/TC 261, Additive manufacturing, in cooperation with ASTM Committee F42, Additive Manufacturing
Technologies, on the basis of a partnership agreement between ISO and ASTM International with the aim to create a common set of
ISO/ASTM standards on additive manufacturing, and in collaboration with the European Committee for Standardization (CEN) Technical
Committee CEN/TC 438, Additive manufacturing, in accordance with the Agreement on technical cooperation between ISO and CEN (Vienna
Agreement).
This second edition of ISO/ASTM 52900 replaces the first edition (ISO/ASTM 52900:2015), which has been technically revised. The main
changes compared to the previous edition are as follows:

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ISO Standard for Additive Manufacturing
ISO/ASTM 52900:2021(en) Additive manufacturing — General principles — Fundamentals and vocabulary
AM: process of joining materials to make parts (3.9.1) from 3D model
data, usually layer (3.3.7) upon layer, as opposed to subtractive
manufacturing and formative manufacturing methodologies

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Test
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https://mitsloan.mit.edu/ideas-made-to-matter/additive-manufacturing-
explained
Additive manufacturing, explained by Rebecca Link
Test Link https://forms.gle/JB3crW17pL24Hsn3A

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Case Study
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General Electricals LEAP Fuel Nozzle
https://www.youtube.com/watch?v=rMzVSbNebCg&t=16s

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Case Study
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General Electricals LEAP Fuel Nozzle
https://youtu.be/RDsAXsiJVy4

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Case Study
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Fado Group - 3D Printing in Tooling applications - Introduct
to Conformal Cooling
https://youtu.be/oZ-06FC6XJA

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Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 68
General Integration of an AMMachine

1. Polymers
2. Metals
3. Ceramics
4. Composites
Polymers
a) ABSpolymer
b) Acrylics
c) Cellulose
d) Nylon
e) Polycarbonate
f) Thermoplastic polyester
g) Polyethylene
h) Polypropylene
i) Polyvinylchloride
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Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 69
Material Classification

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Thank you

References
https://www.lboro.ac.uk/research/amrg/about/the7categoriesofa
dditivemanufacturing/
https://altair.com/newsroom/articles/the-seven-categories-of-
additive-manufacturing-technologies
https://mitsloan.mit.edu/ideas-made-to-matter/additive-
manufacturing-explained
https://additivemanufacturing.com/basics/

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