The document provides an overview of eight additive manufacturing processes including vat photopolymerization, extrusion, material jetting, binder jetting, multi jet fusion, laser sintering, laser melting, sheet lamination, and bioprinting. Each method is described in terms of materials used, layer thickness, tolerances, and manufacturers involved, highlighting the technological advancements and applications in various industries. The document also mentions the availability of a recorded webinar and further resources for learning about these technologies.

1. What Do You Know About
the Eight Additive
Manufacturing Processes?

2. Thank You To Our Sponsor

3. q This webinar will be available afterwards at
www.designworldonline.com & email
q Q&A at the end of the presentation
q Hashtag for this webinar: #DWwebinar
Before We Start

4. Moderator
Leslie Langnau
Design World

5. What do you know about
the 8+ additive
manufacturing processes?

6. • Vat photopolymerization
o Stereolithography and DLP

7. Extrusion
3dp Unlimited
Afinia

8. Material Jetting
Binder Jetting
Multi Jet Fusion

9. Laser sintering
o Variations: Selective Laser Sintering (SLS), Direct Metal Laser Sintering,
Direct Metal Sintering, Electron Beam Melting, Direct Energy Deposition
• Laser melting
o Selective Laser Melting (SLM), LaserCUSING, Electron Beam Melting
• Sheet Lamination
• Bioprinting

10. • Manufacturers:
o 3D Systems
o EnvisionTec
o Form Labs
o Others
Vat Photopolymerization

11. Stereolithography

12. • Vat of photo curable liquid polymer
• Light sources: lasers, ultraviolet, LEDs
• Objects often built upside down, top of
part down
Excellent for fine detail, accurate
dimensions
Layer thickness: 0.002 in. to
0.006 in.
Tolerances: +/- 0.002 to +/- 0.005

13. ProjetX950 uses two
lasers. Spot size ranges
from 0.005 to 0.030 in.

14. Digital Light Processing
• Light source is usually
Blue Light from a
projector, LEDs, or
lasers. Projector optics
enable an XY resolution of
16 to 69 microns.

15. 3SP: Scan, Spin, Selectively
Photocure
Blue Ray light DLP lasers
Layer thickness ranges from
0.002 to 0.004 in.
Resolution is 0.004 in.

16. Extrusion
A thermoplastic filament moves through a
heated deposition nozzle head and is
deposited in layers to build a part.
As material hardens, it binds to previous
layers.
ABS, PLA, and others. Materials often the
same as those used in injection molding.
Photo source: Zureks

17. Layer height ranges from 0.01 to
0.016, and is dependent on the type
of filament and nozzle size used.
Tolerance ranges from +/- 0.005 to
0.10
On the highest-performance
Stratasys FDM machines, part
tolerance reaches as high as 0.003
in., which rivals injection molding.

18. Material Jetting
Sprays or jets drops of liquid
photopolymer onto a build
platform or part.
Usually UV cured
Some systems spray wax material

19. Material Jetting
Finishes tend to be smooth, with
fine detail
Use multiple nozzles
Jetting material can have
different durometers
For form, fit and function apps

20. Material Jetting
Stratasys with its Objet and Solidscape
systems.
Layers: between 16 and 30 microns
(depending on print speed)
Resolution: about 42 microns in each
direction.
3D Systems, Potentially Hewlett-Packard,
which uses a mix of material jetting and
binder jetting

21. Binder jetting
Photo source: ExOne

22. Binder Jetting
Systems jet or spray a binder material onto a layer of
powder material.
Heat is not always used to help bind the layers.
Materials include: ceramic, composites, plastics, sand, and
some metals.
First technology to introduce color: more than 4,000
colors available.

23. Binder Jetting
Post processing used to produce
various properties in the final part,
remove the binder material, or to
consolidate the core material.
Infiltration materials include wax,
cyanoacrylate glue, and epoxy
3D Systems, ExOne, Voxeljet
Architectural structure built by Voxeljet

24. Binder jetting
Parts made in this way are usually
99.9% dense
Minimum layer thickness is 0.0035 in.
Typical tolerance is +/- 0.005 in.
3D Systems binder jetting

25. Multi Jet Fusion—HP
Seems to use both binder and material
jetting technology
Multiple fluids consisting of fusing and
detailing agents (binder, color, and
other)

27. Multi Jet Fusion
Dual carriage
arrangement
Prints more than
30 million drops
per second
Initial material:
thermoplastics

28. Metal sintering and melting
To avoid patent infringement, companies have resorted
to a variety of methods to sinter or melt metal, and have
developed different labels for these methods.

29. Laser Sintering
ASTM: Laser sintering is the production of objects from
powdered materials using one or more lasers to selectively
fuse or melt the particles at the surface, layer by layer, in an
enclosed chamber.

30. Laser Sintering
Materials: Plastic or metal in powder form
From 99+ to 100% dense parts

32. Selective Laser Sintering
Developed and patented by Dr. Carl Deckard, at
University of Texas
One or more thermal sources are used to fuse powder
particles.
Materials include plastic, ceramic, glass, and metal.
Layer thickness is about 0.004 in.
Tolerance is about +/- 0.007 in.

33. Direct Metal Laser Sintering
Developed by Pierre Ciraud in the 1970s.
This is now EOS trademarked technology.
DMLS refers specifically to the use of
metals as the build material
Layer thickness ranges from 20 to 40
microns
Pre and post-run tooling not required.

34. Direct Metal Sintering
3D Systems metal sintering
process
Creates chemically pure, fully
dense metal and ceramic
parts.
Repeatability is about 20
microns

35. Direct Energy Deposition
Optomec’s version is also called blown powder additive manufacturing
Benefits: large build volume, thin layer deposits of 100 nm,
feature sizes to 10 microns

36. Selective Laser Melting
In laser melting, the material is fully
melted into a liquid form
Melting imparts different properties to
the final part, including different crystal
structure or porosity
Renishaw and SLM Solutions

37. LaserCUSING
From Concept Laser, this is a form of laser
melting.
Main differences: Red Fiber laser
Patented exposure strageties
Single component metal powders
Parts are stress and deformation free and fully
dense
Layer thickness is between 20 and 50 microns

38. ASTM classified EBM as a powder bed fusion
technique.
EBM is proprietary to ARCAM
The power source is an electron beam rather
than a laser
A true vacuum is needed to build parts, which
are fully dense
Markets include medical, aerospace, and
automotive
Electron Beam Melting

39. Sheet lamination
Traditionally, this has been a process
that laminates sheets of paper to create
parts.
New companies are using lamination to
build parts layer by layer using other
materials, including metal and carbon
fiber composites

40. Sheet Lamination
Mcor Technologies is the most
known developer of this technology
today.
Selective Deposition Lamination
(SDL) is the name of its process
Standard paper is the material.
SDL combines lamination and binder
jetting to additively build a part
Full-color is available

41. Sheet Lamination

42. Bio-printing
Organovo and EnvisionTec
It’s the process of building spatially
controlled cell patterns using 3D
printing techniques. Cells are dispensed
onto a biocompatible scaffold layer by
layer
EnvisionTec’s process uses syringes to
deposit cell material as the syringes
move in three dimensions
Still undergoing study
Heart valve tissue

43. Questions?
Leslie Langnau
Design World
llangnau@wtwhmedia.com
Twitter: @DW_3DPrinting

44. Thank You
q This webinar will be available at
designworldonline.com & email
q Tweet with hashtag #DWwebinar
q Connect with Design World
q Discuss this on EngineeringExchange.com