1) Additive manufacturing (AM) technologies like selective laser sintering (SLS) and selective laser melting (SLM) can be used to print metal components in a layer-by-layer process, offering advantages over conventional machining like design freedom and the ability to integrate multiple parts.
2) The document discusses screening current conventionally-made products and components to identify opportunities to redesign them using AM technologies to achieve competitive advantages not possible through conventional manufacturing.
3) An example of exploring AM opportunities is through a workshop identifying "killer applications" by examining how AM can strengthen competitive advantages through attributes like shorter time-to-market, customization, and mass reduction.
Integrating parametric design with robotic additive manufacturing for 3D clay...Antonio Arcadu
ABSTRACT This paper presents an ongoing work in relation to the development of a parametric design algorithm and an automated system for additive manufacturing that aims to be implemented in 3D clay printing tasks. The purpose of this experimental study is to establish a first insight and provide information as well as guidelines for a comprehensive and robust additive manufacturing methodology that can be implemented in the area of 3D clay printing, aiming to be widely available and open for use in the relevant construction industry. Specifically, this paper emphasizes on the installation of an industrial extruder for 3D clay printing mounted on a robot, on toolpath planning process using a parametric design environment and on robotic execution of selected case studies. Based on existing 3D printing technology principles and on available rapid prototyping mechanisms, this process suggests an algorithm for system’s control as well as for robotic toolpath development applied in additive manufacturing of small to medium objects. The algorithm is developed in a parametric associative environment allowing its flexible use and execution in a number of case studies, aiming to tentatively test the effectiveness of the suggested robotic additive manufacturing workflow and their future implementation in large scale examples.
Autors: O. Kontovourkisa and G. Tryfonos
The document discusses additive manufacturing (AM) techniques for thermoplastics. It describes fused deposition modeling (FDM) as the most commonly used AM process, where a plastic filament is heated and extruded through a nozzle to build 3D objects layer by layer. Common thermoplastics used in FDM include ABS, PLA, and nylon. The document outlines applications of FDM like rapid prototyping, manufacturing tools, and customized medical and consumer products. It concludes by discussing the company's vision to support 3D printing innovation in India through testing and collaboration with research organizations.
Tc manufacturing technologies 2018s_v2_10_30_18_sJurgen Daniel
The document provides an overview of additive manufacturing (AM) technologies, with an emphasis on 3D printing. It discusses conventional manufacturing versus AM, advantages of AM such as design freedom and reduced waste. Several AM technologies are described, including fused deposition modeling (FDM), stereolithography (SLA), selective laser sintering (SLS), and multi-jet fusion. Application areas for AM like aerospace, automotive, medical and more are highlighted. The document aims to give a broad technology overview while noting that continuous innovation leads to new developments.
3D printing, also known as additive manufacturing, involves building 3D objects from a digital file by laying down successive layers of material under computer control. It allows objects to be created with almost any shape or geometry in a process where layers of material are formed under computer control to produce an object. 3D printers can use materials like plastic, metal, concrete, or even food to construct physical objects from 3D model data layer by layer until the object is complete.
This document discusses the impact of 3D printing on industrial manufacturing. It provides an overview of 3D printing technologies and capabilities, as well as trends in the 3D printing industry such as revenue growth projections and the involvement of large companies. The document also examines threats and opportunities that 3D printing presents for industrial manufacturing, such as the potential replacement of metal cutting, forming, and plastics machinery over time as 3D printing technology advances.
This document discusses additive manufacturing (AM), also known as 3D printing. It begins with definitions of AM and similar terms. Key benefits of AM include increased design freedom, lighter weight structures, and the ability to create complex internal channels or combine multiple parts. The document outlines several industrial sectors utilizing AM like aerospace, energy, and medical. Specific defects that can occur in AM materials if process parameters are incorrect include unmolten powder particles, lacks of fusion, pores, cracks, inclusions, residual stresses, and poor surface roughness.
3D printing market - a global study (2014-2022)BIS Research
The report presents a detailed market analysis of 3D printing and Additive Manufacturing by incorporating complete pricing and cost analysis of 3D printers and materials. Besides porter’s and PESTLE analysis of the market have also been done. The report deals with all the driving factors, restraints, and opportunities with respect to the 3D printing and Additive Manufacturing market, which are helpful in identifying trends and key success factors for the industry.
Lastly, the current market landscape is covered with detailed competitive landscape and company profiles of all key players across the ecosystem. The report also formulates the entire value chain of the market, along with industry trends of 3D printing application industries and materials used with emphasis on market timelines & technology road-maps
Integrating parametric design with robotic additive manufacturing for 3D clay...Antonio Arcadu
ABSTRACT This paper presents an ongoing work in relation to the development of a parametric design algorithm and an automated system for additive manufacturing that aims to be implemented in 3D clay printing tasks. The purpose of this experimental study is to establish a first insight and provide information as well as guidelines for a comprehensive and robust additive manufacturing methodology that can be implemented in the area of 3D clay printing, aiming to be widely available and open for use in the relevant construction industry. Specifically, this paper emphasizes on the installation of an industrial extruder for 3D clay printing mounted on a robot, on toolpath planning process using a parametric design environment and on robotic execution of selected case studies. Based on existing 3D printing technology principles and on available rapid prototyping mechanisms, this process suggests an algorithm for system’s control as well as for robotic toolpath development applied in additive manufacturing of small to medium objects. The algorithm is developed in a parametric associative environment allowing its flexible use and execution in a number of case studies, aiming to tentatively test the effectiveness of the suggested robotic additive manufacturing workflow and their future implementation in large scale examples.
Autors: O. Kontovourkisa and G. Tryfonos
The document discusses additive manufacturing (AM) techniques for thermoplastics. It describes fused deposition modeling (FDM) as the most commonly used AM process, where a plastic filament is heated and extruded through a nozzle to build 3D objects layer by layer. Common thermoplastics used in FDM include ABS, PLA, and nylon. The document outlines applications of FDM like rapid prototyping, manufacturing tools, and customized medical and consumer products. It concludes by discussing the company's vision to support 3D printing innovation in India through testing and collaboration with research organizations.
Tc manufacturing technologies 2018s_v2_10_30_18_sJurgen Daniel
The document provides an overview of additive manufacturing (AM) technologies, with an emphasis on 3D printing. It discusses conventional manufacturing versus AM, advantages of AM such as design freedom and reduced waste. Several AM technologies are described, including fused deposition modeling (FDM), stereolithography (SLA), selective laser sintering (SLS), and multi-jet fusion. Application areas for AM like aerospace, automotive, medical and more are highlighted. The document aims to give a broad technology overview while noting that continuous innovation leads to new developments.
3D printing, also known as additive manufacturing, involves building 3D objects from a digital file by laying down successive layers of material under computer control. It allows objects to be created with almost any shape or geometry in a process where layers of material are formed under computer control to produce an object. 3D printers can use materials like plastic, metal, concrete, or even food to construct physical objects from 3D model data layer by layer until the object is complete.
This document discusses the impact of 3D printing on industrial manufacturing. It provides an overview of 3D printing technologies and capabilities, as well as trends in the 3D printing industry such as revenue growth projections and the involvement of large companies. The document also examines threats and opportunities that 3D printing presents for industrial manufacturing, such as the potential replacement of metal cutting, forming, and plastics machinery over time as 3D printing technology advances.
This document discusses additive manufacturing (AM), also known as 3D printing. It begins with definitions of AM and similar terms. Key benefits of AM include increased design freedom, lighter weight structures, and the ability to create complex internal channels or combine multiple parts. The document outlines several industrial sectors utilizing AM like aerospace, energy, and medical. Specific defects that can occur in AM materials if process parameters are incorrect include unmolten powder particles, lacks of fusion, pores, cracks, inclusions, residual stresses, and poor surface roughness.
3D printing market - a global study (2014-2022)BIS Research
The report presents a detailed market analysis of 3D printing and Additive Manufacturing by incorporating complete pricing and cost analysis of 3D printers and materials. Besides porter’s and PESTLE analysis of the market have also been done. The report deals with all the driving factors, restraints, and opportunities with respect to the 3D printing and Additive Manufacturing market, which are helpful in identifying trends and key success factors for the industry.
Lastly, the current market landscape is covered with detailed competitive landscape and company profiles of all key players across the ecosystem. The report also formulates the entire value chain of the market, along with industry trends of 3D printing application industries and materials used with emphasis on market timelines & technology road-maps
The document discusses additive manufacturing (AM) processes and applications in construction. It provides an overview of AM, including common processes like material extrusion and powder bed fusion. Examples of AM construction projects are described, such as a printed office building and hotel. Key challenges in applying AM to large-scale construction include developing suitable feedstock materials that can be extruded while maintaining appropriate properties. Cementitious materials are most commonly used and studies have found optimized mixes include cement, fly ash, silica fume and additives to achieve desired strength and printability.
This document provides an introduction and overview of additive manufacturing (AM). It defines AM as a process of joining materials to make 3D objects layer by layer, and describes some key aspects including input, methods, materials, and applications. The document discusses how AM has advanced rapidly in recent decades, providing advantages like the ability to directly produce complex parts in a relatively short time without tools or molds. Historical developments are outlined, showing how AM technologies have evolved from early systems in the 1980s to many commercial options today.
Additive manufacturing (AM) involves joining materials layer by layer to make 3D objects based on digital models, unlike subtractive methods. The main steps are modeling, printing, and finishing. In modeling, 3D models are created through CAD, 3D scanning, or photogrammetry. In printing, errors are eliminated and the model is sliced into thin layers for deposition. In finishing, parts may be printed oversized and finished for higher precision. Common AM materials include plastics like ABS and metals like steel. Advantages are faster production, lower waste, and complex designs, while disadvantages include slow speeds, costs, and limited size.
This document summarizes a seminar on additive manufacturing (AM) presented by Ankush Kalia. It defines AM as a process that builds 3D objects by joining materials layer by layer under computer control using a 3D printer. The key steps in AM are modeling, printing, and finishing. Different AM methods are classified and compared in terms of design flexibility, cost of complexity, accuracy, assembly needs, and production efficiency. Capabilities of AM like multi-material printing and applications in areas like rapid prototyping, food, apparel, vehicles, firearms, medicine, bioprinting, space, and education are discussed. Current barriers to AM like scalability, resolution, material properties, and reliability are also presented
Additive Manufacturing Technologies 2019_v1sJurgen Daniel
The document provides an overview of additive manufacturing (AM) technologies, with a focus on 3D printing. It discusses how AM techniques like laser powder bed fusion and binder jetting can 3D print parts in metals and ceramics. AM offers benefits over conventional manufacturing like reduced waste and complexity of designs. The document also examines applications of AM in industries like aerospace, medical, and electronics, providing examples of 3D printed engine parts, implants, and circuits.
3D printing is called as additive manufacturing technology where a three dimensional object is created by laying down successive layers of material. It is also known as rapid prototyping, is a mechanized method whereby 3D objects are quickly made on a reasonably sized machine connected to a computer containing blueprints for the object. It is working under the principle of Fused Deposition Modelling (FDM). The 3D printing concept of custom manufacturing is exciting to nearly everyone. The basic principles include materials cartridges, flexibility of output, and translation of code into a visible pattern.3D Printers are the machines that produce physical 3D models from digital data by printing layer by layer. It can make physical models of objects either designed with a CAD program or scanned with a 3D Scanner. Here we are going to propose a model report on design and fabrication of a 3D printer.
This document discusses 3D printing, including its history and various methods such as selective laser sintering, stereolithography, and fused deposition modeling. It describes how 3D printing works and some business impacts like reduced inventory and just-in-time production. The document also covers new developments like 3D printed cars and buildings, as well as challenges involving health impacts, material properties, and potential economic effects.
This document provides an overview of additive manufacturing (AM) processes. It discusses various AM techniques such as vat photopolymerization, material jetting, binder jetting, material extrusion, and powder bed fusion. For each technique, it describes the process, developments in the field, limitations and suitable materials. It emphasizes that powder bed fusion is currently the most used platform for functional parts but requires an expert user to optimize trade-offs for part quality.
in this presentation i have discussed about 4D Printing technology. you can watch out it in video form on my You Tube channel https://youtu.be/ZDaurFz2byc
6 Key Takeaways for the State of 3D Printing - 2016Sculpteo
Our 2016 edition of The State of 3D Printing is out. Almost 1000 participants responded and shared their experience and expectations about 3D printing bringing incomparable depth to this survey. You'll find the latest trends in the 3D printing industry and know how to gear up your 3D printing strategy for success.
Additive manufacturing Processes PDF by (badebhau4@gmail.com)Er. Bade Bhausaheb
Additive manufacturing (AM) processes build three-dimensional objects by adding material layer by layer based on a digital model. The document discusses several AM processes including powder bed fusion which uses lasers or electron beams to fuse powder materials together layer by layer. Key powder bed fusion techniques are direct metal laser sintering
3D Printing Technology seminar report by ajaysingh_02AjaySingh1901
This is the Report file about 3D Printing Technolog and additive manufacturing in which we cover all the basics of 3DP
History,need, development,scope, availablity,future scope,trend before the 3DP, Advantage and disadvantages, limitations, Application and Appliances.
3D printing technology, also known as additive manufacturing, builds objects layer by layer under computer control. It is increasingly being used in the aerospace industry to produce complex parts. While 3D printing allows greater design flexibility and lower costs than traditional manufacturing, wider adoption is limited by issues like speed of production and reliability testing of printed parts. Future advances may enable on-demand printing of replacement parts in space and the mass production of entire aircraft structures with 3D printing.
3D printing is a method of additive manufacturing that builds 3D objects layer by layer by adding material. It allows for tangible goods to be produced from a digital design. There are several methods of 3D printing including selective laser sintering (SLS), stereolithography, fused deposition modeling (FDM), and polyjet matrix technology that use different materials and processes. 3D printing has applications across many industries like medical, mechanical, architecture, fashion, and jewelry for prototyping, production, and customized parts.
3D printing technology was originally developed at MIT in 1993. Z Corporation commercialized this technology as 3D Printing (3DP) and was later acquired by 3D Systems, who renamed it Color Jet Printing (CJP). CJP uses inkjet printing heads to bind layers of powder to build 3D objects layer-by-layer. 3D Systems' current CJP printers range from desktop models to larger industrial machines, and can produce parts in plastic, metal, or ceramic materials.
This document discusses 3D printing technology and its uses. It describes how 3D printing works by using a digital 3D design to build an object in layers by depositing material. The document outlines the benefits of 3D printing such as customization, complexity of designs, being tool-less, sustainability, and allowing imagination. It also provides details about the jewelkreator 3D printer, its specifications, applications in areas like medical implants, consumer products, architecture, and industry.
This document summarizes a technical seminar on 3D printing presented by B.Vineetha. It discusses the history and development of 3D printing, how 3D printers work by building objects layer by layer from a digital design. It describes common 3D printing methods like stereolithography, selective laser sintering, and fused deposition modeling. The document also covers applications of 3D printing in fields like industrial design, medicine, fashion, and more. It concludes that 3D printing offers advantages like time and cost savings compared to traditional manufacturing.
The document describes an additive manufacturing course, including its textbooks, learning outcomes, and modules. Specifically:
- The course covers additive manufacturing processes using polymers, powders, and nanomaterials. Students will analyze characterization techniques and describe NC/CNC programming and automation.
- Module 1 introduces additive manufacturing, covering its evolution, processes, classifications, post-processing, guidelines for process selection, and applications.
- The module discusses the additive manufacturing process chain from CAD to part build and removal, and classifies AM into liquid polymer, particle, molten material, and solid sheet systems.
1) Additive manufacturing (AM) technologies like selective laser sintering and selective laser melting allow for the production of metal parts layer by layer from powder beds.
2) AM offers advantages over conventional machining like design freedom, ability to produce complex geometries, and potential for part consolidation and mass reduction.
3) Identifying components suitable for AM redesign requires understanding how AM technologies can enable new design opportunities rather than just copying conventional designs. AM works best for customized parts and can allow for surface curvature, lattice structures for mass optimization, and integrated multi-part designs.
3D Printing Market ( A comprehensive study on Material ( MEtal, PLastics, Cer...BIS Research Inc.
The report has covered more than 50 players involved in the 3D printing and Additive Manufacturing technology.
The report presents a detailed market analysis of 3D printing and Additive Manufacturing by incorporating complete pricing and cost analysis of components & products, product benchmarking, Porter’s analysis and PEST (Political, Economic, Social & Technological factor) analysis of the market. Market Classification encompasses segmentation & sub-segmentation of the market by Technology, Materials, Application industry and Geography.
The report deals with all the driving factors, restraints, and opportunities with respect to the 3D printing and Additive Manufacturing market, which are helpful in identifying trends and key success factors for the industry. Lastly, the current market landscape is covered with detailed competitive landscape and company profiles of all key players across the ecosystem. The report also formulates the entire value chain of the market, along with industry trends of 3D printing application industries and materials used with emphasis on market timelines & technology roadmaps, and market & product life cycle analysis.
Lastly, the 3D printing and Additive Manufacturing market is segmented by geography across North America, South & Central America, Europe, Asia-Pacific and ROW (Rest of the World) and further sub-segmented by countries. Country specific market is estimated and the growth opportunities are identified.
Adaptation for AM (AfAM) modifies existing product designs to better suit additive manufacturing, leveraging some AM benefits within existing design constraints. Design for AM (DfAM) takes a blank-sheet approach, fully exploiting AM opportunities without constraints and allowing influence over system-level design decisions. An example compares a conventional hydraulic manifold design to an adapted and designed for AM solution. The adapted design reduces weight by 78% over conventional, while the designed for AM solution reduces it by 91%, showing increased benefits of moving from adaptation to designing specifically for AM.
The document discusses additive manufacturing (AM) processes and applications in construction. It provides an overview of AM, including common processes like material extrusion and powder bed fusion. Examples of AM construction projects are described, such as a printed office building and hotel. Key challenges in applying AM to large-scale construction include developing suitable feedstock materials that can be extruded while maintaining appropriate properties. Cementitious materials are most commonly used and studies have found optimized mixes include cement, fly ash, silica fume and additives to achieve desired strength and printability.
This document provides an introduction and overview of additive manufacturing (AM). It defines AM as a process of joining materials to make 3D objects layer by layer, and describes some key aspects including input, methods, materials, and applications. The document discusses how AM has advanced rapidly in recent decades, providing advantages like the ability to directly produce complex parts in a relatively short time without tools or molds. Historical developments are outlined, showing how AM technologies have evolved from early systems in the 1980s to many commercial options today.
Additive manufacturing (AM) involves joining materials layer by layer to make 3D objects based on digital models, unlike subtractive methods. The main steps are modeling, printing, and finishing. In modeling, 3D models are created through CAD, 3D scanning, or photogrammetry. In printing, errors are eliminated and the model is sliced into thin layers for deposition. In finishing, parts may be printed oversized and finished for higher precision. Common AM materials include plastics like ABS and metals like steel. Advantages are faster production, lower waste, and complex designs, while disadvantages include slow speeds, costs, and limited size.
This document summarizes a seminar on additive manufacturing (AM) presented by Ankush Kalia. It defines AM as a process that builds 3D objects by joining materials layer by layer under computer control using a 3D printer. The key steps in AM are modeling, printing, and finishing. Different AM methods are classified and compared in terms of design flexibility, cost of complexity, accuracy, assembly needs, and production efficiency. Capabilities of AM like multi-material printing and applications in areas like rapid prototyping, food, apparel, vehicles, firearms, medicine, bioprinting, space, and education are discussed. Current barriers to AM like scalability, resolution, material properties, and reliability are also presented
Additive Manufacturing Technologies 2019_v1sJurgen Daniel
The document provides an overview of additive manufacturing (AM) technologies, with a focus on 3D printing. It discusses how AM techniques like laser powder bed fusion and binder jetting can 3D print parts in metals and ceramics. AM offers benefits over conventional manufacturing like reduced waste and complexity of designs. The document also examines applications of AM in industries like aerospace, medical, and electronics, providing examples of 3D printed engine parts, implants, and circuits.
3D printing is called as additive manufacturing technology where a three dimensional object is created by laying down successive layers of material. It is also known as rapid prototyping, is a mechanized method whereby 3D objects are quickly made on a reasonably sized machine connected to a computer containing blueprints for the object. It is working under the principle of Fused Deposition Modelling (FDM). The 3D printing concept of custom manufacturing is exciting to nearly everyone. The basic principles include materials cartridges, flexibility of output, and translation of code into a visible pattern.3D Printers are the machines that produce physical 3D models from digital data by printing layer by layer. It can make physical models of objects either designed with a CAD program or scanned with a 3D Scanner. Here we are going to propose a model report on design and fabrication of a 3D printer.
This document discusses 3D printing, including its history and various methods such as selective laser sintering, stereolithography, and fused deposition modeling. It describes how 3D printing works and some business impacts like reduced inventory and just-in-time production. The document also covers new developments like 3D printed cars and buildings, as well as challenges involving health impacts, material properties, and potential economic effects.
This document provides an overview of additive manufacturing (AM) processes. It discusses various AM techniques such as vat photopolymerization, material jetting, binder jetting, material extrusion, and powder bed fusion. For each technique, it describes the process, developments in the field, limitations and suitable materials. It emphasizes that powder bed fusion is currently the most used platform for functional parts but requires an expert user to optimize trade-offs for part quality.
in this presentation i have discussed about 4D Printing technology. you can watch out it in video form on my You Tube channel https://youtu.be/ZDaurFz2byc
6 Key Takeaways for the State of 3D Printing - 2016Sculpteo
Our 2016 edition of The State of 3D Printing is out. Almost 1000 participants responded and shared their experience and expectations about 3D printing bringing incomparable depth to this survey. You'll find the latest trends in the 3D printing industry and know how to gear up your 3D printing strategy for success.
Additive manufacturing Processes PDF by (badebhau4@gmail.com)Er. Bade Bhausaheb
Additive manufacturing (AM) processes build three-dimensional objects by adding material layer by layer based on a digital model. The document discusses several AM processes including powder bed fusion which uses lasers or electron beams to fuse powder materials together layer by layer. Key powder bed fusion techniques are direct metal laser sintering
3D Printing Technology seminar report by ajaysingh_02AjaySingh1901
This is the Report file about 3D Printing Technolog and additive manufacturing in which we cover all the basics of 3DP
History,need, development,scope, availablity,future scope,trend before the 3DP, Advantage and disadvantages, limitations, Application and Appliances.
3D printing technology, also known as additive manufacturing, builds objects layer by layer under computer control. It is increasingly being used in the aerospace industry to produce complex parts. While 3D printing allows greater design flexibility and lower costs than traditional manufacturing, wider adoption is limited by issues like speed of production and reliability testing of printed parts. Future advances may enable on-demand printing of replacement parts in space and the mass production of entire aircraft structures with 3D printing.
3D printing is a method of additive manufacturing that builds 3D objects layer by layer by adding material. It allows for tangible goods to be produced from a digital design. There are several methods of 3D printing including selective laser sintering (SLS), stereolithography, fused deposition modeling (FDM), and polyjet matrix technology that use different materials and processes. 3D printing has applications across many industries like medical, mechanical, architecture, fashion, and jewelry for prototyping, production, and customized parts.
3D printing technology was originally developed at MIT in 1993. Z Corporation commercialized this technology as 3D Printing (3DP) and was later acquired by 3D Systems, who renamed it Color Jet Printing (CJP). CJP uses inkjet printing heads to bind layers of powder to build 3D objects layer-by-layer. 3D Systems' current CJP printers range from desktop models to larger industrial machines, and can produce parts in plastic, metal, or ceramic materials.
This document discusses 3D printing technology and its uses. It describes how 3D printing works by using a digital 3D design to build an object in layers by depositing material. The document outlines the benefits of 3D printing such as customization, complexity of designs, being tool-less, sustainability, and allowing imagination. It also provides details about the jewelkreator 3D printer, its specifications, applications in areas like medical implants, consumer products, architecture, and industry.
This document summarizes a technical seminar on 3D printing presented by B.Vineetha. It discusses the history and development of 3D printing, how 3D printers work by building objects layer by layer from a digital design. It describes common 3D printing methods like stereolithography, selective laser sintering, and fused deposition modeling. The document also covers applications of 3D printing in fields like industrial design, medicine, fashion, and more. It concludes that 3D printing offers advantages like time and cost savings compared to traditional manufacturing.
The document describes an additive manufacturing course, including its textbooks, learning outcomes, and modules. Specifically:
- The course covers additive manufacturing processes using polymers, powders, and nanomaterials. Students will analyze characterization techniques and describe NC/CNC programming and automation.
- Module 1 introduces additive manufacturing, covering its evolution, processes, classifications, post-processing, guidelines for process selection, and applications.
- The module discusses the additive manufacturing process chain from CAD to part build and removal, and classifies AM into liquid polymer, particle, molten material, and solid sheet systems.
1) Additive manufacturing (AM) technologies like selective laser sintering and selective laser melting allow for the production of metal parts layer by layer from powder beds.
2) AM offers advantages over conventional machining like design freedom, ability to produce complex geometries, and potential for part consolidation and mass reduction.
3) Identifying components suitable for AM redesign requires understanding how AM technologies can enable new design opportunities rather than just copying conventional designs. AM works best for customized parts and can allow for surface curvature, lattice structures for mass optimization, and integrated multi-part designs.
3D Printing Market ( A comprehensive study on Material ( MEtal, PLastics, Cer...BIS Research Inc.
The report has covered more than 50 players involved in the 3D printing and Additive Manufacturing technology.
The report presents a detailed market analysis of 3D printing and Additive Manufacturing by incorporating complete pricing and cost analysis of components & products, product benchmarking, Porter’s analysis and PEST (Political, Economic, Social & Technological factor) analysis of the market. Market Classification encompasses segmentation & sub-segmentation of the market by Technology, Materials, Application industry and Geography.
The report deals with all the driving factors, restraints, and opportunities with respect to the 3D printing and Additive Manufacturing market, which are helpful in identifying trends and key success factors for the industry. Lastly, the current market landscape is covered with detailed competitive landscape and company profiles of all key players across the ecosystem. The report also formulates the entire value chain of the market, along with industry trends of 3D printing application industries and materials used with emphasis on market timelines & technology roadmaps, and market & product life cycle analysis.
Lastly, the 3D printing and Additive Manufacturing market is segmented by geography across North America, South & Central America, Europe, Asia-Pacific and ROW (Rest of the World) and further sub-segmented by countries. Country specific market is estimated and the growth opportunities are identified.
Adaptation for AM (AfAM) modifies existing product designs to better suit additive manufacturing, leveraging some AM benefits within existing design constraints. Design for AM (DfAM) takes a blank-sheet approach, fully exploiting AM opportunities without constraints and allowing influence over system-level design decisions. An example compares a conventional hydraulic manifold design to an adapted and designed for AM solution. The adapted design reduces weight by 78% over conventional, while the designed for AM solution reduces it by 91%, showing increased benefits of moving from adaptation to designing specifically for AM.
1) The document discusses guidelines for designing parts to be manufactured through additive manufacturing (AM) processes like selective laser melting (SLM) and fused deposition modeling (FDM).
2) Key considerations in the design guidelines include minimizing staircasing effects, properly orienting parts for printing, adding support structures where needed, and designing for easy removal of support structures and excess powder.
3) Thermal management during the printing process is also an important factor, as the laser or nozzle injects significant heat into the part being printed. Thin-walled structures may require increasing cross-sections or internal grids to promote heat dissipation.
UK ATC 2015: Optimisation Driven Design and Additive Manufacturing Applied fo...Altair
The document describes the optimization driven design and additive manufacturing process applied to an antenna bracket for the ESA Sentinel-1 satellite. Topology optimization was used to reduce the mass of the original design by over 40% while improving structural performance. The optimized design was additively manufactured in metal powder and underwent rigorous testing to verify structural integrity for the space mission.
Design Faster and Lighter: Applications of Topology Optimization In Additive ...Altair
The document discusses how topology optimization and additive manufacturing can be used together to design lighter and more efficient parts. It explains that topology optimization uses mathematics to optimize a part's material layout based on load conditions to create stronger yet lighter designs. Combining these approaches allows for complex geometries not possible with traditional methods. Several industry examples are presented that achieved significant weight reductions and performance improvements through this integrated design process.
Design Optimization of Axles using Inspire and OptiStructAltair
This document summarizes the use of topology optimization at AAM Products to reduce weight and improve performance of automotive axle designs. It describes how AAM uses Inspire and Optistruct software to perform topology optimizations that consider multiple load cases, manufacturing constraints, and target mass reductions. An example optimization of a carrier design is presented, showing a 20% mass reduction while improving gear deflection performance. The process involves defining design spaces, applying manufacturing and load constraints, setting multi-physics optimization targets, and validating optimized designs through hardware testing. Topology optimization has allowed AAM to develop manufacturable, mass-reduced axle part designs that show performance improvements.
Design Methodologies for ALM and Lattice partsAltair
Design for additively made parts has become a very hot topic. Many engineers see the potential for topology optimization when designing ALM parts, but once they start the workflow, they tend to get bogged down in how to complete the process.
This document discusses design considerations for additive manufacturing (AM) with metals. It outlines that while AM provides design freedom, there are still capabilities and limitations to consider. Key factors for metal AM include minimum feature size due to laser spot diameter, avoiding large overhangs and interior holes that require supports, minimizing supports through feature shape and part orientation, and preventing part distortion from residual stress. The document presents a case study comparing a conventional hydraulic manifold design to designs adapted and purposefully designed for AM, showing increased mass savings as the design leverages more AM capabilities. True design for AM allows for an extremely efficient design that consolidates parts and is self-supporting. Understanding AM characteristics is important for successful design.
Leveraging Geometric Shape Complexity, in Optimal Design for Additive Manufac...Altair
This document summarizes several case studies that leverage additive manufacturing capabilities by developing structural designs with increased geometric complexity through topology optimization. Case studies included an aircraft door hinge, formula race car upright, and UAV fuselage internal structure. Topology optimization was used to develop designs optimized for additive manufacturing without constraints, allowing greater geometric complexity compared to conventional manufacturing. Post-processing was required to define surfaces and sizes for final designs. Observations noted additive manufacturing enables designs matching physics for weight reduction, and increased downstream optimization is needed to satisfy all criteria.
Structural Component Design Optimization for Additive ManufactureAltair
1) The document discusses using topology optimization software to design structural components optimized for additive manufacturing.
2) Case studies include designing an aircraft door hinge and a formula race car upright, comparing designs optimized for conventional vs additive manufacturing.
3) Topology optimization allowed designs optimized for additive manufacturing to be up to 33% lighter than conventionally optimized designs by taking advantage of the ability to add complexity without constraints of traditional manufacturing methods.
The document provides an overview of 3D printing technologies for industrial applications. It discusses various 3D printing processes such as binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, sheet lamination, and vat photopolymerization. For each process, it describes the basic method, key companies, available materials, applications, and typical price ranges for systems. It also covers trends such as hybrid systems that combine 3D printing with milling or other subtractive processes. The document aims to outline the current state of the art in industrial 3D printing.
Join us for an all-encompassing look at industrial 3D printing – where the technology is today, how it got there, and where it’s heading. Early adopters are using 3D printing to improve product design, streamline manufacturing processes, and lean out their supply chains. Cutting-edge software is being used alongside 3D printing to design previously “impossible,” parts optimized beyond conventional manufacturing capabilities.
This document discusses the growing use of additive manufacturing (AM) in metal production. It is being used to produce parts for aerospace and medical implant industries. AM allows for design freedom, weight reduction, customized structures, and lower production costs compared to conventional casting and machining. The objective is to transform metal manufacturing industries by transitioning from traditional methods to AM. Major industries like aerospace are embracing AM for cost savings and performance benefits. The future outlook is that AM will become a primary production method for industries like aerospace and medical implants.
The document discusses additive manufacturing (AM) techniques like direct metal laser sintering (DMLS) and selective laser sintering (SLS). It describes how AM works by building 3D objects layer by layer from a digital model. The document outlines various AM techniques, materials used, industries adopting AM, benefits like reduced tooling and weight optimization, limitations like large volume production issues. It provides examples of companies like EOS that manufacture AM equipment and cost illustrations. Application examples discussed are aerospace parts, potential aero engine parts, and the outlook for AM.
The document discusses opportunities in 3D printing of metals from 2016 to 2026. It provides an overview of the technology landscape for 3D printing metals, including the main production techniques of selective laser melting, electron beam melting, blown powder, metal + binder systems, and welding. Each technique is assessed in terms of their strengths, weaknesses, opportunities, and threats. Key application areas are also outlined, such as aerospace, medical, dental, and more. The document is authored by Rachel Gordon from IDTechEx, who leads research on 3D printing and additive manufacturing.
Car makers have to reduce consumption of vehicles and so, are continually looking for solutions to lighten components. For powertrain, components generally mean screwed assembly, contact and fitting interfaces, with different kind of loading to take into account (static and dynamic). Hence, we decided to apply with Altair assistance, a process of topology optimization on an assembly of gearbox housing in order to check its feasibility and efficiency. Several steps had to be solved from exhaustive identification of all mechanical constraints to execution of large models with Optistruct. By the end, the process has been defined and implemented on an existing gearbox and will be soon apply on the next one to design.
Speakers
Philippe Dausse, Modelization Specialist, PSA Peugeot Citroen Automobiles
Additive Manufacturing (AM) is undergoing a revolution as it moves from the model and tooling shop and onto the factory floor. A growing range of firms are deploying AM to create innovative new products that deliver increased performance in use and which could not be produced conventionally. Here we explore the drivers behind this transition and the increased demands that series production places on AM to deliver predictable, consistent parts. We look at the chains of linked processes and tools that are needed to create an integrated manufacturing process with AM at its heart, and the controls that must be employed to make AM a mainstream manufacturing process.
The document discusses additive manufacturing (AM) techniques for thermoplastics. It describes fused deposition modeling (FDM) as the most commonly used AM process, where a plastic filament is extruded through a heated nozzle to build 3D objects layer by layer. Common thermoplastics used in FDM include ABS, PLA, and nylon. The document outlines applications of FDM such as rapid prototyping, manufacturing tools, small series production, and customized medical devices. It concludes by outlining the company's vision to support 3D printing innovation in India through testing and collaboration with research organizations.
The document provides an introduction to additive manufacturing (AM) including definitions, principles, types of prototypes, advantages, and commonly used terms. It discusses how AM works by building 3D objects layer by layer from a digital file. Key points covered include the 7 main AM processes classified by ISO/ASTM, the history and development of stereolithography, and benefits of AM for designers, engineers, and manufacturing.
The document provides an introduction to additive manufacturing (AM) including definitions, principles, types of prototypes, advantages, and commonly used terms. It discusses how AM works by building 3D objects layer by layer from a digital file. Key points covered include the 7 main AM processes classified by ISO/ASTM, the history and development of stereolithography, and benefits of AM for designers, engineers, and manufacturing.
This document provides information about 3D printing from the National Institute of Technology in Hamirpur, India. It defines 3D printing as a process that creates physical objects by depositing material layer by layer based on a digital model. The document then discusses the history and development of 3D printing, including the first commercial 3D printer in 1987, and covers various 3D printing technologies, materials, applications and benefits and limitations.
Feasibility study on stereolithography apparatus sla and selective laser si...IAEME Publication
The document discusses a feasibility study comparing Stereolithography Apparatus (SLA) and Selective Laser Sintering (SLS) additive manufacturing technologies. Test specimens were designed and built using the Accura 60 material on an SLA system and the Duraform PA/Nylon material on an SLS system. The specimens were then subjected to mechanical tests including tension testing, compression testing, and hardness testing. Scanning electron microscope (SEM) images were also taken of fractured surfaces to examine the internal structures and causes of failure. The results of the experimentation were used to determine which material demonstrated better mechanical properties for the given applications.
Rapid prototyping (RP) uses 3D printing technologies to automatically construct physical models from CAD data. This allows designers to quickly create prototypes rather than just 2D pictures. All RP techniques involve (1) creating a CAD file, (2) converting it to STL format, (3) slicing the STL file into thin layers, (4) constructing the model layer-by-layer, and (5) cleaning and finishing the prototype. The most common techniques are stereolithography, which solidifies liquid resin with UV light, and laminated object manufacturing, which bonds sheets of material like paper or metal powder. RP saves significant time and cost over traditional prototyping methods.
Rapid prototyping refers to technologies that can automatically construct physical models from CAD data. These technologies allow designers to quickly create tangible prototypes rather than just 2D pictures. The document discusses several rapid prototyping techniques including stereolithography, laminated object manufacturing, selective laser sintering, fused deposition modeling, solid ground curing, and 3D inkjet printing. All techniques involve slicing a 3D CAD model into layers and building the model layer-by-layer. Rapid prototyping enables faster and cheaper prototype production compared to traditional methods, facilitating improved product design and testing.
The document summarizes additive manufacturing (AM) techniques. It discusses the history of AM, which began in 1984 with the development of stereolithography. It then describes common AM processes like fused deposition modeling, selective laser sintering, laminated object manufacturing and stereolithography. Advantages of AM include reduced costs, ability to create complex geometries, and on-location manufacturing. Disadvantages include high machine costs and slow print speeds. Applications discussed include use in the medical, automotive, and construction industries. The scope of AM is growing with the creation of the first 3D printed car and plans for 3D printed buildings.
3d printing technology,
Machines available for 3d printing,
Industrial application of 3D printing technology,
Machines available in market for 3D printing,
Types of 3D printing,
Metal 3D printing,
Products manufactured by 3D printing,
Future scope of manufacturing by 3D printing.
Rapid prototyping (RP) has emerged as a key enabling technology that can shorten product design and development time. This article discusses the role of RP in 'time compression' engineering and provides a brief description of three RP processes: stereolithography, selective laser sintering, and fused deposition modelling. The article also outlines different applications of RP technology in areas like functional models, patterns for investment casting, and medical/surgical models. Finally, it discusses future developments needed to further advance this field.
This document provides an overview of 3D printing technology. It discusses what 3D printing is, how the process works by creating a virtual design and then layering materials, and some common methods and technologies used like selective laser sintering and fused deposition modeling. Applications mentioned include rapid prototyping to save time and costs as well as personal printing. The document also notes the industry is growing and will change manufacturing and commerce, while challenges include costs, limited materials per machine, standard file formats, and printing speed.
The document provides an overview of additive manufacturing technologies and their evolution. It discusses several technologies such as stereolithography, laminated object manufacturing, fused deposition modeling, selective laser sintering, and multijet modeling. It also highlights recent projects applying these technologies to areas like aerospace, automotive, consumer goods, medicine, and marine. Finally, it discusses the growth of the market for plastic materials used in additive manufacturing and new materials being developed.
This document summarizes a seminar on additive manufacturing technologies. It discusses the history of 3D printing, which was developed in 1984. It then describes several common additive manufacturing techniques like selective laser sintering, fused deposition modeling, and stereolithography. Applications of 3D printing discussed include uses in architecture, automotive, medical, food, and aerospace. The document outlines advantages like reduced costs and complex geometries along with disadvantages like high machine costs and size limitations. It concludes by noting the growing scope of additive manufacturing.
Industrial adoption of 3D Printing has been increasing gradually from prototyping to manufacturing of low volume customized parts. The need for customized implants like tooth crowns, hearing aids, and orthopedic-replacement parts has made the life sciences industry an early adopter of 3D Printing. Demand for low volume spare parts of vintage cars and older models makes 3D printing very useful in the automotive industry. It is possible to 3D print in a wide range of materials that include thermoplastics, thermoplastic composites, pure metals, metal alloys and ceramics. Right now, 3D printing as an end-use manufacturing technology is still in its infancy. But in the coming decades, and in combination with synthetic biology and nanotechnology, it has the potential to radically transform many design, production and logistics processes.
3 D printing principle and potential application in aircraft industryBruno Niyomwungeri
This document discusses the history and development of 3D printing technology from its origins in the 1980s to current applications in the aircraft industry. It outlines several common 3D printing techniques like selective laser sintering, thermal inkjet printing, and fused deposition modeling. It then provides examples of how 3D printing is used in the aircraft industry in China and elsewhere to produce complex titanium and metal parts with significant cost and material savings compared to traditional manufacturing. The document concludes by discussing potential future applications of 3D printing within aerospace like printing entire aircraft wings or more engine parts.
Additive manufacturing (3D printing) is increasingly used in medical applications. It allows for customization and complex designs not possible with traditional manufacturing. The document discusses several 3D printing methods - Fused Deposition Modeling (FDM), Polymer Laser Sintering (PLS), Direct Metal Sintering (DMS), and Continuous Liquid Interface Production (CLIP). Each uses different materials and processes, with tradeoffs in speed, resolution, and cost. Emerging technologies like CLIP promise significantly faster printing times. Validation is still needed to ensure 3D printed medical parts meet regulatory standards for safety and efficacy.
3D Printing (Additive Manufacturing) PPT & PDFmangadynasty5
Definition:
3D Printing, also known as Additive Manufacturing (AM), is a revolutionary manufacturing process that constructs three-dimensional objects layer by layer from a digital model. Unlike traditional subtractive manufacturing methods that involve cutting or shaping material to create an object, 3D printing adds material gradually, allowing for highly complex and customized designs.
3D printing technology builds objects layer by layer from digital models, opening new possibilities in design and customization. It is hailed as a versatile and disruptive technology that will transform sectors like healthcare, aerospace, education, and consumer goods. 3D printing works by building up layers of materials like plastic or metal to form objects. It is used to create models, prototypes, tools, spare parts, and more. The choice of materials depends on the type of 3D printing and the object's requirements, with common materials including plastics, metals, ceramics, and composites.
1. EXPLORING OPPORTUNITIES FOR ADDITIVE MANUFACTURING ■
nr 6 2014 MIKRONIEK 53
IN SEARCH OF OPTIMAL
COMPONENT DESIGN
To identify components currently made by conventional machining
technology that are suitable for redesign within Additive Manufacturing
(AM) technology, it is essential to have a good understanding of the
distinctive properties AM technology has to offer. This article provides
a brief introduction, with a particular focus on metal printing. An
overview is then given of the questions to be asked for screening the
current (conventionally machined) product/component portfolio
regarding their AM potential. Finally, an example underlines the
importance of modifying component design to enable optimal AM.
Introduction
What is nowadays commonly called ‘Additive
Manufacturing’ (AM), started as ‘Rapid Prototyping’ in the
mid-Eighties. The first commercially available 3D printer
was based on the stereo lithography principle, where an
(X, Y)-controlled UV light beam hardened out a layer of
liquid plastic on a software-controlled (Z) build platform.
The value of this novel technology was soon observed
within the design and fashion industry for the purpose of
rapid prototyping (3D printing).
Since then a lot has changed and currently a manifold of
3D printing technologies exists, each having specific
characteristics to serve a share of market demand. All
technologies have two things in common.
Firstly, building up a component by means of AM
technology is done layer by layer (after addition of a new
layer of the native component, the build platform is lowered
by a layer thickness to enable building up the next layer).
Secondly, the interface language between the CAD system
and the 3D printer is based on the STL (Surface Tessellation
Language) interface format. The STL files describe only the
surface geometry of a three-dimensional object without any
representation of colour, texture or other common CAD
model attributes. An STL file describes a raw, unstructured
triangulated surface by the unit normal and vertices
(ordered by the right-hand rule) of the triangles using a
three-dimensional Cartesian coordinate system.
Since the introduction of low-cost FDM (Fused Deposition
Modelling, see Figure 1) printers ( 300-2,500) some years
ago, 3D printing has become extremely popular and has
entered the consumer market. In an FDM printer a plastic
wire (filament) is fed into a heated extruder where the solid
plastic is weakened and pressed through a nozzle. This
nozzle is moved in the (X,Y) surface by means of a
software-controlled gantry. The movement path of the
nozzle equals the slice outline of the layer to be built. Below
this nozzle there is a build platform which is lowered each
time a layer of the object has been built.
SJEF VAN GASTEL
AUTHOR’S NOTE
Sjef van Gastel is Director of
Innovative Production
Technologies at Fontys
Hogeschool Engineering, part
of Fontys University of Applied
Sciences in Eindhoven, the
Netherlands. He also is
Technologies & Patents
Manager at Assembléon, in
Veldhoven, the Netherlands.
s.vangastel@fontys.nl
www.fontys.nl
www.assembleon.com
2. ■ EXPLORING OPPORTUNITIES FOR ADDITIVE MANUFACTURING
1
54 MIKRONIEK nr 6 2014
Laser Melting, see Figure 2). SLS and SLM are related
technologies, where a metal or plastic/ceramic powder is
distributed equally in a thin layer over a build platform
(powder bed), by means of a roller or a squeegee. Typical
layer thickness is around 25-100 μm. An (X,Y)-controlled
laser beam melts (or sinters) the powder particles in the
build layer together. After building a slice of the
component, the platform will lower over one layer thickness
and a new layer of powder will be applied over the previous
one.
Here the powder bed will be heated to reduce too large
temperature differences between the particles that should
be joined together and the superfluous particles. Also, the
atmosphere inside the machine should be low in oxygen
content to reduce unwanted oxidation. This can be attained
by applying a nitrogen or argon atmosphere or by means of
evacuation. After the component has been built, the super-fluous
powder should be removed (after cooling the
component down to room temperature).
In the case of the SLS process the part density will typically
be around 95-98%, and particles have only been partially
attached to each other, resulting in a brittle structure. To
obtain a better, stronger higher-density object, sintering at
elevated temperatures will be needed. In the SLM process
(metal-only) density will be around 100% and sintering is
not necessary.
Comparing AM to conventional machining
As stated earlier, most machine factories and machine
shops are not aware yet of the benefits of AM technology.
In conventional machining of components all processes are
executed sequentially and material is removed from the
starting material until the desired object (final component)
is attained. The biggest benefit of conventional machining
is that component quality (tolerances, surface roughness) is
(still) superior to the quality of an AM component.
However, there are also many disadvantages, such as: work
preparation covering all sequential fabrication steps,
limitations in component shaping (for example: curved
holes are not possible), many different tools being required
(costs, tool wear), many different machines being required
(lathes, milling, grinding, welding, drilling, etc.), and most
of the starting material isn’t used for the final component
but is removed in the form of chips.
AM technology, on the other hand, is a single
manufacturing process where all shapes of the final
component are realised in a (single) manufacturing stage.
However, in most cases (partial) machining of the AM
component will still be needed to achieve the desired
tolerances and surface finish.
Most AM technology in use nowadays is related to
consumer applications (3D printing of plastic objects).
However AM technology also offers great benefits for
industrial applications (plastic, metal and ceramic objects).
Some (pioneering) companies have already noticed these
benefits and have invested in 3D printing equipment.
Metal printing
The most commonly used technology for printing of metal
parts is SLS (Selective Laser Sintering) or SLM (Selective
ObjeXlab
1 Fused Deposition
Modelling (FDM)
printing principle.
Nowadays, many initiatives are taken to introduce 3D printing
technology for educational purposes (FabLabs, public libraries,
schools). Because of its inspiring feedback between the design of an
object and the physical object, 3D printing has become an important
factor in stimulating students to opt for a technical education.
At Fontys University of Applied Sciences in Eindhoven an initiative was
taken in 2012 to set up a laboratory for AM, called ‘ObjeXlab’. ObjeXlab
aims for a public-private cooperation to explore AM opportunities by
means of applied research projects focussed on the Dutch Brainport
area. ObjeXlab is part of the Centre of Expertise High Tech Systems &
Materials at Fontys.
Projects are manned by both industry participants (engineers,
researchers) and educational participants (students, teachers). The
outcome of these collaboration projects will be benefi cial both for
industry (student talent scouting, project results, facility sharing) and
for education (education of students, training of staff in emerging
technologies, knowledge for curriculum).
3. ‘AM killer applications’ workshop
To help identify the opportunities for AM within a
company’s product portfolio, the ObjeXlab (see the text
box) has developed the ‘AM killer applications’ workshop.
In this workshop the ability of AM to achieve competitive
advantages via product attributes that would be impossible
using conventional manufacturing technology will be
investigated. The following questions need to be answered
to identify these opportunities.
• What are the main points of distinction of a company’s
products compared to its competitors:
– How is this distinction realised?
– What are the typical product attributes that determine
nr 6 2014 MIKRONIEK 55
this distinction?
• Which (components of a) product(s) determine(s) this?
• Are there typical attributes of AM (shorter time-to-market,
customisation, design freedom, mass reduction,
integration of functions) that could strengthen the
competitive advantage?
• If so, what (sub) components are eligible?
Exploring opportunities for AM technology
To identify components (currently made by conventional
machining technology) for redesign within AM technology,
it is essential to have a good understanding of the
distinctive properties AM technology has to offer. It makes
no sense to copy conventional components exactly by
means of AM. This will lead, in most cases, to more
expensive components of inferior quality. So, what are the
distinctive properties of AM?
First of all, AM is extremely suitable for unique, one-of-a-kind,
components. Consider here, for instance, personalised
items such as personal gifts, medical implants (jaw
implants, skull implants, knee joints) and medical aids
(hearing aids, ear shells, orthotics, dentures).
Secondly, AM allows more freedom in shaping component
surfaces, such as external curvature and curved holes. These
curved holes, for example, can improve heat transfer in
integrated heat exchangers.
Thirdly, it is possible to make components with variable
mass density, using lattices (see Figure 3). These lattices
enable mass reduction and stiffness optimisation in
machine design.
Fourthly, it will be possible to combine functionality of
multiple individual components into one integrated
component, enabling both cost reduction and improved
functionality. A new EU-funded project (‘Femtoprint’) is
exploring the limitations of 3D printing, for example,
regarding integrated miniature 3D printed components
(see Figure 4).
Finally, one can benefit from specific properties of 3D
printed components, such as the ‘orange peel’ of SLM
components for optical mounts to reduce internal light
reflections or the porosity of SLS components to apply in
vacuum grippers.
2 Selective Laser Melting
(SLM) printing principle.
3 3D printed metal
component with internal
lattice structure.
4 Example of an
integrated miniature 3D
printed component. [1]
2
3
4
4. ■ EXPLORING OPPORTUNITIES FOR ADDITIVE MANUFACTURING
56 MIKRONIEK nr 6 2014
final shape. The team then sent the finished brackets to
GE Global Research (GRC) in Niskayuna, New York, for
destruction testing. GRC engineers strapped each bracket
onto an MTS servo-hydraulic testing machine and exposed
it to axial loads ranging from 35.6 to 42.2 kN. Only one of
the brackets failed and the rest advanced to a torsion test,
where they were exposed to torque of 565 Nm. This GE jet
engine bracket challenge is an excellent illustration that
emphasises the importance of modification of component
design to enable optimal Additive Manufacturing.
• Can the potential benefits of the identified components
be quantified? (e.g. cost reduction, lead time reduction,
performance)
• How would one rank the identified opportunities, when
an assessment is made of efforts (risks) versus the
potential reward?
• What are the most promising application(s) for AM?
GE design challenge
To illustrate the effect of optimising a machine component
for AM technology, GE organised a design challenge for
engineering students in June 2013, the GE jet engine
bracket challenge [2]. Loading brackets onto jet engines
plays a very critical role: they must support the weight of
the engine during handling without breaking or warping.
These brackets may be used only periodically, but they stay
on the engine at all times, including during flight. The
original bracket that GE challenged participants to redesign
(see Figure 5) via 3D printing methods, weighed 2033
grams. The winner was able to reduce its weight by nearly
84%, to just 327 grams (see Figure 6).
GE Aviation 3D printed the ten shortlisted designs at its
AM plant in Cincinnati, Ohio. GE workers made the
brackets from a titanium alloy on an SLM machine, which
uses a laser beam to fuse layers of metal powder into the
5 Original jet engine
loading bracket (milled).
6 The winning design (3D
printed using SLM
technology).
REFERENCE
[1] V. Tielen and Y. Bellouard, “Three-Dimensional Glass Monolithic
Micro-Flexure Fabricated by Femtosecond Laser Exposure and
Chemical Etching”, Micromachines, 2014, 5, pp. 697-710.
[2] www.ge.com/about-us/openinnovation
OBJEXLAB WORKSHOP
An optimal design, combined with AM, will
strengthen a company’s competitive edge.
Interested parties are invited to contact the
ObjeXlab, which will be happy to organise an
in-company ‘AM killer applications’ workshop.
WWW.OBJEXLAB.COM
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