ADDITIVE MANUFACTURING, 3D PRINTING, COMPUTER CONTROLLED PROCESS
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Additive manufacturing, often referred to as 3D printing, is a computer-controlled process for creating 3D objects
ADDITIVE MANUFACTURING, 3D PRINTING, COMPUTER CONTROLLED PROCESS
- 1. Additive Manufacturing Assistant Professor Mr. CH D JAYA TEJA M. Tech (Ph.D.) BONAM VENKATA CHALAMAYYA ENGINEERING COLLEGE(A) -ODALAREVU
- 2. Additive manufacturing: Additive manufacturing, often referred to as 3D printing, is a computer-controlled process for creating 3D objects. • As the name implies, objects are built up by ‘adding’ material — usually a plastic, ceramic, or metal powder — to a build platform in thin layers, which are hardened using a curing agent, heat, or a laser beam.
- 3. Additive manufacturing, also known as 3D printing, involves creating objects layer by layer from a digital design. the key steps in the process: 1.Designing the Model: Start with a 3D design using computer-aided design (CAD) software. The design can be created from scratch or obtained from a library of models. 2.File Preparation: Convert the design into a format that the 3D printer can understand, such as STL (Stereolithography) or OBJ files. Slice the model into layers using slicing software, which generates the G-code for the printer. 3.Material Selection: Choose the material based on the desired properties of the final product. Materials can range from plastics and metals to ceramics and composites. 4.Printing: The 3D printer creates the object layer by layer. Different techniques, such as Fused Deposition Modeling (FDM), Stereolithography (SLA), or Selective Laser Sintering (SLS), are used depending on the material and application. 5.Post-Processing: After printing, the object might require finishing touches like sanding, polishing, painting, or removing support structures. 6.Inspection and Testing: The final product is inspected for quality and may undergo testing to ensure it meets the required specifications.
- 4. Classification in additive manufacturing (AM) typically refers to categorizing the various technologies and techniques used in the 3D printing process. These are generally classified based on the method of material deposition, bonding, or sintering. 1. Material Extrusion • Technologies like Fused Deposition Modeling (FDM). • Material, often thermoplastics, is extruded through a nozzle to build layers. 2. Vat Photopolymerization • Includes techniques like Stereolithography (SLA) and Digital Light Processing (DLP). • Uses liquid photopolymer resin cured by light to create solid layers. 3. Powder Bed Fusion (PBF) • Techniques such as Selective Laser Sintering (SLS) and Selective Laser Melting (SLM). • Layers of powdered material (metal, plastic, or ceramic) are fused using a laser or electron beam. 4. Binder Jetting • Involves depositing a liquid binding agent onto a powder bed to form solid layers. • Common materials include sand, ceramics, and metals.
- 5. 5. Material Jetting • Similar to inkjet printing but deposits liquid material layer by layer, which hardens through curing. 6. Sheet Lamination • Combines layers of sheet materials using adhesives or ultrasonic welding. • Primarily used for creating composite materials. 7. Directed Energy Deposition (DED) • Involves melting material (metal, in most cases) as it is being deposited, often using lasers, electron beams, or plasma arcs. • Each of these classifications has its unique applications, advantages, and limitations, making AM a diverse and versatile technology
- 6. 1. Material Extrusion • Example: A desktop 3D printer using PLA or ABS filament for prototyping, hobbyist projects, or educational tools. 2. Vat Photopolymerization • Example: Printing intricate jewelry or dental molds using resin-based SLA printers, such as Formlabs Form 3. 3. Powder Bed Fusion (PBF) • Example: Producing aerospace components with titanium alloy using Selective Laser Melting (SLM). 4. Binder Jetting • Example: Manufacturing sand-based molds for metal casting or creating full-color prototypes using gypsum powder. 5. Material Jetting • Example: Printing high-resolution product prototypes or anatomical models for healthcare using PolyJet technology. 6. Sheet Lamination • Example: Creating composite material prototypes or large-scale models using Ultrasonic Additive Manufacturing (UAM) with aluminum sheets. 7. Directed Energy Deposition (DED) • Example: Repairing turbine blades or adding material to existing parts using metal powders and laser-based DED systems.
- 8. Classification Description Example Material Extrusion Thermoplastic materials are extruded through a nozzle to build layers. Prototyping using PLA or ABS filament with a desktop 3D printer. Vat Photopolymerization Liquid resin is cured using light to create solid layers. Dental molds or jewelry printing with SLA printers like Formlabs Form 3. Powder Bed Fusion (PBF) Powdered materials are fused using laser or electron beams. Aerospace components made with titanium alloy using Selective Laser Melting (SLM). Binder Jetting Liquid binding agents are deposited onto powder beds to form layers. Sand-based molds for metal casting or full-color prototypes using gypsum powder. Material Jetting Liquid material is deposited in layers and hardened through curing. High-resolution anatomical models for healthcare using PolyJet technology. Sheet Lamination Sheets of material are bonded together using adhesives or ultrasonic welding. Composite material prototypes or large-scale models created with Ultrasonic Additive Manufacturing (UAM). Directed Energy Deposition (DED) Material is deposited and melted simultaneously using lasers, electron beams, or plasma arcs. Repairing turbine blades or adding material to existing parts with laser-based DED systems.
- 9. Additive Manufacturing (AM) offers several advantages that have revolutionized the way products are designed and manufactured. Here are some key benefits: 1.Design Flexibility: AM allows for the creation of complex geometries and intricate designs that traditional manufacturing methods cannot achieve. This opens up new possibilities for innovation and creativity. 2.Material Efficiency: Since AM builds objects layer by layer, it minimizes waste compared to subtractive methods like machining, where excess material is removed. 3.Cost-Effective for Prototypes and Small Batches: AM is ideal for prototyping and producing small quantities, as it eliminates the need for expensive molds or tooling. 4.Customization: Products can be easily tailored to meet specific requirements, whether it's personalizing medical implants or customizing consumer goods. 5.Rapid Production: AM can significantly reduce lead times, enabling faster product development and quicker responses to market demands.
- 10. 6. Reduced Inventory Costs: On-demand manufacturing eliminates the need for large inventories, as parts can be printed as needed. 7. Lightweight Structures: AM enables the creation of lightweight yet strong structures, which are especially valuable in industries like aerospace and automotive. 8. Localized Production: It supports decentralization, allowing production closer to the point of use, reducing transportation costs and environmental impact. 9. Wide Range of Materials: From plastics to metals, AM accommodates diverse materials, catering to a variety of applications. 10. Sustainability: The efficiency and reduced waste in AM contribute to a more sustainable manufacturing approach.
- 11. Additive manufacturing (AM) supports a wide range of materials, each chosen based on the desired properties and applications. Here's an overview of the types of materials used in AM: 1. Polymers • Thermoplastics: Materials like PLA, ABS, PETG are widely used for prototyping and consumer products. • Resins: Photopolymers are used in Vat Photopolymerization processes for high-resolution applications. • Flexible Polymers: TPU for applications requiring elasticity and durability. 2. Metals • Titanium: Lightweight and strong, ideal for aerospace and medical implants. • Aluminum: Used for automotive parts due to its lightweight nature. • Steel: Common in tools and industrial applications. • Nickel Alloys: For high-temperature and corrosive environments, used in energy and aerospace industries. 3. Ceramics • Materials like alumina, zirconia, or silicon carbide are used for medical implants and high- temperature applications.
- 12. 4. Composites • Carbon Fiber Reinforced Polymers (CFRP): Provide high strength and lightweight properties for automotive and aerospace industries. • Metal Matrix Composites (MMC): Combine metal with reinforcing particles for enhanced durability. 5. Biomaterials • Biocompatible Polymers: Used in healthcare for prosthetics and implants. • Hydrogels: For tissue engineering and bioprinting applications. 6. Others • Sand and Gypsum: Binder jetting processes for molds and prototypes. • Precious Metals: Gold and silver for jewelry manufacturing