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Introduction to Additive Manufacturing(3D printing)

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vijimech408

In this presentation you will learn steps involved in 3D printing

Engineering
Related topics:
Additive Manufacturing
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DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T ADDITIVE MANUFACTURING (20IP653) Module-1 Introduction Course Instructor Vijay Praveen P M Assistant Professor Department of I&P Engg.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 2 SYLLABUS Introduction: Introduction to Prototyping, Traditional Prototyping Vs. Rapid Prototyping (RP), and classification of Rapid Manufacturing Processes: Additive, Subtractive, Formative, Generic RP process. Overview of additive manufacturing– History – Need- Classification -Additive Manufacturing Technology in product development-Materials for Additive Manufacturing Technology – Tooling – Applications
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 3
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 4 Types of Industrial Design Prototyping • Iterative Prototyping • Parallel Prototyping • Rapid Prototyping • Iterative Prototyping • Iterative prototyping involves creating a prototype from the product design, testing it for usability and functionality, and then revising what didn’t work. After testing has concluded, the research team will design a new iteration and manufacture it for testing.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 5 • Parallel Prototyping • On the other hand, parallel prototyping is a concept-based method where several design concepts are compared concurrently. Multiple designs are drafted and then compared to find the best versions before a physical prototype is manufactured. • Rapid Prototyping (High fedlity protoype) • Rapid prototyping is a more recent product design testing method that incorporates some aspects of the iterative process. This method is fast and accessible for product designers who can access CAD software and 3D printing technology in-house. Rapid prototyping utilizes innovative technologies—CAD software and 3D printing—to create seamless data transfer from computer to printer
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 6
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 7 Roles of the Prototypes (1) Experimentation and learning (2) Testing and proofing (3) Communication and interaction (4) Synthesis and integration (5) Scheduling and markers
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 8 (1) Experimentation and learning To the product development team, prototypes can be used to help the thinking, planning, experimenting and learning processes while designing the product. Questions and doubts regarding certain issues of the design can be addressed by building and studying the prototype For example, in designing the appropriate elbow-support of an office chair, several physical prototypes of such elbow supports can be built to learn about the “feel” of the elbow support when performing typical tasks on the office chair
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 9 (2) Testing and proofing Prototypes can also be used for testing and proofing of ideas and concepts relating to the development of the product. For example, in the early design of folding reading glasses for the elderly, concepts and ideas of folding mechanism can be tested by building rough physical prototypes to test and prove these ideas to see if they work as intended
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 10 (3) Communication and interaction The prototype also serves the purpose of communicating information and demonstrating ideas, not just within the product development team, but also to management and client (whether in house or external). Nothing is clearer for explanation or communication of an idea than a physical prototype where the intended audience can have the full experience of the visual and tactile feel of the product For example, a physical prototype of a cellular phone can be presented to carefully selected customers. Customers can handle and experiment with the phone and give feedback to the development team on the features of and interactions with the phone, thus providing valuable information for the team to improve its design
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 11 (4) Synthesis and integration A prototype can also be used to synthesize the entire product concept by bringing the various components and sub-assemblies together to ensure that they will work together. This will greatly help in the integration of the product and surface any problems that are related to putting the product together
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 12 (5) Scheduling and markers Prototyping also serves to help in the scheduling of the product development process and is usually used as markers for the end or start of the various phases of the development effort. Each prototype usually marks a completion of a particular development phase, and with proper planning, the development schedule can be enforced
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 13 Rapid Prototyping (RP) • the goal is to preplan a part to make it as simple as possible in order to get it quickly and cheaply. Therefore, rapid prototyping parts generally cannot be used as final products.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 14 Rapid prototyping again is subdivided into 1.solid imaging or concept modeling, and 2. functional prototyping. Solid imaging or concept modeling: If a rapid prototyping part is made mainly for 3D visualization, it is called a solid image, a concept model, a mock-up, or even a rapid mock-up.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 15 If a part has a single or some of the functionalities of the latter product, it can be used to verify this aspect of the engineering design. Consequently it is called a functional prototype
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 16 HISTORICAL DEVELOPMENT The development of Rapid Prototyping is closely tied in with the development of applications of computers in the industry. The declining cost of computers, especially of personal and mini computers, has changed the way a factory works. The increase in the use of computers has spurred the advancement in many computer- related areas including Computer-Aided Design (CAD), Computer-Aided Manufacturing (CAM) and Computer Numerical Control (CNC) machine tools. In particular, the emergence of RP systems could not have been possible without the existence of CAD
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 17
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 18
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 19 Classification Rapid Manufacturing (RM) process/RP
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 20 1.subtractive process, one starts with a single block of solid material larger than the final size of the desired object and material is removed until the desired shape is reached. Ex: milling, turning, drilling, sawing, grinding 2. Additive process is the exact reverse in that the end product is much larger than the material when it started. A material is manipulated so that successive portions of it combine to form the desired object. Ex: Stereolithography and Selective Laser Sintering 3.formative process is one where mechanical forces or restricting forms are applied on a material so as to form it into the desired shape. Ex: Bending, forging, electromagnetic forming and plastic injection molding
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 21
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 22 FUNDAMENTALS OF RAPID PROTOTYPING 1. A model or component is modeled on a Computer-Aided Design/ Computer- Aided Manufacturing (CAD/CAM) system. The model which represents the physical part to be built must be represented as closed surfaces which unambiguously define an enclosed volume. This means that the data must specify the inside, outside and boundary of the model This requirement will become redundant if the modeling technique used is solid modeling. This is by virtue of the technique used, as a valid solid model will automatically be an enclosed volume. 2. The solid or surface model to be built is next converted into a format dubbed the “STL” (STereoLithography) file format which originates from 3D Systems. The STL file format approximates the surfaces of the model by polygons. Highly curved surfaces must employ many polygons, which means that STL files for curved parts can be very large. However, there are some rapid prototyping systems which also accept IGES (Initial Graphics Exchange Specifications) data, provided it is of the correct “flavor”. 3. A computer program analyzes a STL file that defines the model to be fabricated and “slices” the model into cross sections. The cross sections are systematically recreated through the solidification of either liquids or powders and then combined to form a 3D model.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 23 RP WHEEL
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 24
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 25 Definition: 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. OR Definition: Additive manufacturing (AM) is an additive process of making a three-dimensional solid object of virtually any shape from a digital model, where materials are applied in successive layers under computer control.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 26
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 27
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DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 29
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 30 AM Evolution (History of AM) ● In the 60s Herbert Voelcker had thoughts of the possibilities of using computer aided machine control to run machines that build parts from CAD geometry. ● In the 70s he developed the mathematics to describe 3D aspects that resulted in the first algorithms for solid modeling. ● In the 80s Carl Deckard came up with the idea of layer-based manufacturing. In 1986 Charles hull, of ultra violet products, Inc. Patented this technology, which is now known as stereolithographic. Later on, Charles hull formed 3d systems, Inc. and commercialized this technology. In the years between 1988, when chuck hull's stereolithographic was first made available for public purchase, ● In 1989, Scott Crump patented the FDM (Fused deposition modeling) process, forming the Stratasys Company. ● In 1989 a group from MIT patented the 3D Printing (3DP) process. These processes from 1989 are heavily used today, with FDM variants currently being the most successful. ● Sanders developed ink jet technology process in 1994
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 31 Clay pot making
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 32
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 33 Need for Additive Manufacturing As additive manufacturing evolves, optimizing designs for the technology is becoming ever-more important to unlocking the full potential of the technology. . There are mainly 6 reasons why we need to go for the design for additive manufacturing, they are: 1. Create parts with greater complexity 2. Minimal material waste 3. Simplified assembly 4. Material innovation 5. Cost-effective customization 6. Minimum support structures
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 34
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 35
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 36
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 37 AM v/s CNC
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 38 Difference between AM & CNC machining process • An important difference between additive manufacturing technology and CNC machining process is that a prototype or model is. obtained by layer by layer addition process as opposed to removing material from a 'block'.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 39 Impact of AM Since the emergence of these technologies and companies, the AM industry has been constantly expanding, growing, and advancing with much enthusiasm. With many industries seeing the lucrative value and abilities of AM, the market has been expanding very quickly. Many new types of RP and AM methods have been created since these original pioneers first started developing the technology. Some new technology has been novel and some just variations of the past types. There has also been a lot of development in the materials that can be used as well as research into making their properties optimal for end use.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 40
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 41 Steps in AM Process
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 42
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 43 • The limitation here in STL is only geometry information is stored in files while all other information that a cad model can contain is eliminated such as unit, color, material, etc. which plays a critical role in the functionality of the built part and effects finished parts
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 44 • Once a correct STL file is available, a series of steps is required to transfer the information to start the build. The needed information varies, depending on the technology but in general, these steps start with repairing any errors within the STL file such as gaps between surface triangle facets, inverted normal where the "wrong side" of a triangle facet is identified as the interior of the part. • Series of steps is carried out to correct possible errors in the model file. • These errors can include missing triangles, inverted or double triangles, transverse triangles, open edges and contours, and shells. Each type of error can cause issues in the building process or result in incorrect parts and geometries. • Once the errors have been repaired, proper orientation of the 3d model with respect to the build platform is- decided. Following the orientation, the geometry, density, geometry of support structures are decided and generated in 3d model space and assigned to the part model
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 45 • Machine preparation can roughly be divided into two groups of tasks such as machine hardware set up and process control. • 1) Machine hardware setup: Hardware setup entails cleaning of build chamber from the previous build, loading of powder material, a routine check of all critical build settings and process controls such as gas pressure, flow rate, oxygen sensors, etc. • 2) Process control; The tasks in the, process control group allow an additive manufacturing system • To accept and process the build files • Start the build • Interrupt the build at any given time if desired or required, • Preparing the machine for finished part extraction, • Unloading of material.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 46 • In this step slicer program is used to divide the models into layers in the build direction based on the desired layer thickness. • Ideally, the layer thickness would be slightly larger than the mean diameter of powder to achieve high coupling of laser energy input into the absorption, heating, and melting of powder. • Parameters which determine an amount of energy incident onto the powder bed per unit time, are energy input, beam power, scan speed, and focus move. • Once the slice information is generated, it is transferred into the interface program that runs on am systems. • The interface program serves as the interface between information of the build and machine controls that carry out the actual build process.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 47
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 48
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 49
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 50 Post processing techniques
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 51
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 52
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DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 55
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 56
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 57
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 58
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 59 Advantages of AM: 1. Increased design freedom versus conventional casting and machining 2. Light weight structures, made possible either by the use of lattice design or by designing parts where material is only where it needs to be, without other constraints 3. New functions such as complex internal channels or several parts built in one 4. Speed: one can do complex parts within hours, with limited human resources. The only machine operator is needed for loading the data and powder material, start the process and finally for the finishing. During the manufacturing process no operator is needed. 5. Customization: 3D printing processes allow for mass customization, personalize products according to individual needs and requirements. 6. Sustainable / environmentally friendly: It provides environmental efficiencies in terms of the manufacturing process by utilizing upto 90% of standard materials, and therefore creating less waste.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 60 7. No tools needed, unlike other conventional metallurgy processes which require molds and metal forming or removal tools 8. Short production cycle time: complex parts can be produced layer by layer in a few hours in additive machines. The total cycle time including post processing usually amounts to a few days or weeks and it is usually much shorter than conventional metallurgy processes which often require production cycles of several months. The process is recommended for he production of parts in small series. 9. No storage cost: since 3D printer can print products as and when needed, and does not cost more than mass manufacturing, no expense on storage of goods is required. 10. Increase employment opportunities: Widespread use of 3D printing technology will increase the demand for designers and technicians to operate 3D printers and create blueprints for products.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 61 Limitations ➢ Production series: the AM processes are generally suitable for unitary or small series and is not relevant for mass production. But progresses are made to increase machine productivity and thus the production of larger series. For small sized parts, series up to 25000 parts/year are already possible. ➢ Support material removal: when production volumes are small, the removal of support material is usually not a big issue. When the volumes are high, it becomes an important consideration. ➢ Limitations of raw material: in traditional manufacturing, there are a wide range of materials wherein an additive manufacturing technology-can work with only a few. More research is required to devise methods to enable 3d printed products to be more durable and robust. ➢ Good skills are required for application design and to set process parameters ➢ Material cost: cost of most materials of additive systems is greater than that of those used for traditional manufacturing
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 62 .Material properties: a limited choice of materials is available: Actually, materials and their properties (e.g., tensile property, tensile strength, yield strength, and fatigue) have not been fully characterized. Also, in terms of surface quality, even the best RM processes need perhaps secondary machining and polishing to reach acceptable tolerance and surface finish. Limitations of size: 3d printing technology is currently limited by size constraints. Very large objects are still not feasible when built using 3d printers. Cost of printers: The cost of a 3d printer is high
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 63 Classification of AM according to ASTM
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 64
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 65 Additive Manufacturing Technology in product development • The technology of additive manufacturing/3D printing is divided in two main application levels: • Rapid prototyping • Rapid manufacturing.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 66
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 67 • Rapid prototyping again is subdivided into – solid imaging or concept modeling, – functional prototyping. Solid imaging or concept modeling: If a rapid prototyping part is made mainly for 3D visualization, it is called a solid image, a concept model, a mock-up, or even a rapid mock-up. If a part has a single or some of the functionalities of the latter product, it can be used to verify this aspect of the engineering design. Consequently it is called a functional prototype
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 68
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 69 Direct Manufacturing Direct Manufacturing leads to final parts that directly come from the AM process. It is not important that the available materials show exactly the same physical properties as the materials used within traditional fabrication processes.
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DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 75
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 76
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DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 78
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 79 Two Types of Rapid Tooling: Direct vs. Indirect
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 80 Additive Manufacturing Materials • The main classes of materials used in 3D printing today are – Polymers – Metals – Composites – Ceramics – Sand – Wax
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 81 • Polymers • The first 3D printing process to be developed, stereolithography, is a form of vat polymerization that cures resin to build polymer parts. Polymers are still a widely used class of 3D printed materials today, but have evolved far beyond early, brittle materials • ABS (Acrylonitrile butadiene styrene) • PLA (polylactide), including soft PLA • PC (polycarbonate) • Polyamide (Nylon) • Nylon 12 (Tensile strength 45 Mpa) • Glass filled nylon (12.48 Mpa) • Epoxy resin • Wax • Photopolymer resins
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 82 • Metals • On the metals side, the most commonly 3D printed materials include aluminum, titanium, stainless steel, Inconel and cobalt chrome. • Copper has historically been difficult to 3D print with laser-based systems, but innovations such as blue-light lasers make this possible; reflective metals like this may be easier to print using other methods such as binder jetting. An alloy suitable for one metal 3D printing method may not be appropriate for all such methods. • Metals for 3D printing are generally provided in wire or powder formats, but can also be mixed with other materials. Newer “bound metal deposition” (BMD) systems apply filament or rods consisting of metal powder embedded in polymer to build “green” parts that then achieve their final dimensions and metal properties through firing in an oven, similar to metal injection molding (MIM).
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 83 • Composites Composites that combine different types of materials are also gaining ground in 3D printing. The composite might be created during the 3D printing process, or that process might begin with a material that already includes an additive. Polymers reinforced with chopped carbon and glass fibers are being used for everything from short-run injection molds to composite layup tools to end-use parts, offering an option in between neat plastic and more costly metals. Some 3D printers offer the ability to lay continuous fiber reinforcement simultaneous or interspersed with the 3D printed form; others utilize sheets of reinforcing material fused with layers of polymer. Polymer composites like this can be made strong enough to be an alternative to metal in some cases, often with significant weight savings.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 84 • Ceramics • Ceramics have low absorption and are difficult to print with laser- based systems. However, solutions relying on extrusion, material jetting and photopolymerization have been developed. • Sand • Even sand can be 3D printed through binder jetting to selectively “glue” the grains together, a technique that is quickly advancing for both prototype and production foundry molds as well as vacuum- form
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 85 Important Questions 1) Define prototype and discuss its types. 2) Define RP and discuss its types. 3) Define AM .what are the advantages, disadvantages and its applications. 4) Discuss the Evolution of AM and its classification . 5) Explain AM Process. 6) What are the postprocessing techniques used in AM and explain. 7) What are the difference between Additive and Subtractive manufacturing, 8) What are the difference between CNC and AM. 9) Discuss the AM technology used in Product development. 10) Write a note on materials used in AM.

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Introduction to Additive Manufacturing(3D printing)

  • 1. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T ADDITIVE MANUFACTURING (20IP653) Module-1 Introduction Course Instructor Vijay Praveen P M Assistant Professor Department of I&P Engg.
  • 2. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 2 SYLLABUS Introduction: Introduction to Prototyping, Traditional Prototyping Vs. Rapid Prototyping (RP), and classification of Rapid Manufacturing Processes: Additive, Subtractive, Formative, Generic RP process. Overview of additive manufacturing– History – Need- Classification -Additive Manufacturing Technology in product development-Materials for Additive Manufacturing Technology – Tooling – Applications
  • 3. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 3
  • 4. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 4 Types of Industrial Design Prototyping • Iterative Prototyping • Parallel Prototyping • Rapid Prototyping • Iterative Prototyping • Iterative prototyping involves creating a prototype from the product design, testing it for usability and functionality, and then revising what didn’t work. After testing has concluded, the research team will design a new iteration and manufacture it for testing.
  • 5. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 5 • Parallel Prototyping • On the other hand, parallel prototyping is a concept-based method where several design concepts are compared concurrently. Multiple designs are drafted and then compared to find the best versions before a physical prototype is manufactured. • Rapid Prototyping (High fedlity protoype) • Rapid prototyping is a more recent product design testing method that incorporates some aspects of the iterative process. This method is fast and accessible for product designers who can access CAD software and 3D printing technology in-house. Rapid prototyping utilizes innovative technologies—CAD software and 3D printing—to create seamless data transfer from computer to printer
  • 6. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 6
  • 7. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 7 Roles of the Prototypes (1) Experimentation and learning (2) Testing and proofing (3) Communication and interaction (4) Synthesis and integration (5) Scheduling and markers
  • 8. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 8 (1) Experimentation and learning To the product development team, prototypes can be used to help the thinking, planning, experimenting and learning processes while designing the product. Questions and doubts regarding certain issues of the design can be addressed by building and studying the prototype For example, in designing the appropriate elbow-support of an office chair, several physical prototypes of such elbow supports can be built to learn about the “feel” of the elbow support when performing typical tasks on the office chair
  • 9. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 9 (2) Testing and proofing Prototypes can also be used for testing and proofing of ideas and concepts relating to the development of the product. For example, in the early design of folding reading glasses for the elderly, concepts and ideas of folding mechanism can be tested by building rough physical prototypes to test and prove these ideas to see if they work as intended
  • 10. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 10 (3) Communication and interaction The prototype also serves the purpose of communicating information and demonstrating ideas, not just within the product development team, but also to management and client (whether in house or external). Nothing is clearer for explanation or communication of an idea than a physical prototype where the intended audience can have the full experience of the visual and tactile feel of the product For example, a physical prototype of a cellular phone can be presented to carefully selected customers. Customers can handle and experiment with the phone and give feedback to the development team on the features of and interactions with the phone, thus providing valuable information for the team to improve its design
  • 11. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 11 (4) Synthesis and integration A prototype can also be used to synthesize the entire product concept by bringing the various components and sub-assemblies together to ensure that they will work together. This will greatly help in the integration of the product and surface any problems that are related to putting the product together
  • 12. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 12 (5) Scheduling and markers Prototyping also serves to help in the scheduling of the product development process and is usually used as markers for the end or start of the various phases of the development effort. Each prototype usually marks a completion of a particular development phase, and with proper planning, the development schedule can be enforced
  • 13. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 13 Rapid Prototyping (RP) • the goal is to preplan a part to make it as simple as possible in order to get it quickly and cheaply. Therefore, rapid prototyping parts generally cannot be used as final products.
  • 14. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 14 Rapid prototyping again is subdivided into 1.solid imaging or concept modeling, and 2. functional prototyping. Solid imaging or concept modeling: If a rapid prototyping part is made mainly for 3D visualization, it is called a solid image, a concept model, a mock-up, or even a rapid mock-up.
  • 15. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 15 If a part has a single or some of the functionalities of the latter product, it can be used to verify this aspect of the engineering design. Consequently it is called a functional prototype
  • 16. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 16 HISTORICAL DEVELOPMENT The development of Rapid Prototyping is closely tied in with the development of applications of computers in the industry. The declining cost of computers, especially of personal and mini computers, has changed the way a factory works. The increase in the use of computers has spurred the advancement in many computer- related areas including Computer-Aided Design (CAD), Computer-Aided Manufacturing (CAM) and Computer Numerical Control (CNC) machine tools. In particular, the emergence of RP systems could not have been possible without the existence of CAD
  • 17. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 17
  • 18. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 18
  • 19. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 19 Classification Rapid Manufacturing (RM) process/RP
  • 20. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 20 1.subtractive process, one starts with a single block of solid material larger than the final size of the desired object and material is removed until the desired shape is reached. Ex: milling, turning, drilling, sawing, grinding 2. Additive process is the exact reverse in that the end product is much larger than the material when it started. A material is manipulated so that successive portions of it combine to form the desired object. Ex: Stereolithography and Selective Laser Sintering 3.formative process is one where mechanical forces or restricting forms are applied on a material so as to form it into the desired shape. Ex: Bending, forging, electromagnetic forming and plastic injection molding
  • 21. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 21
  • 22. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 22 FUNDAMENTALS OF RAPID PROTOTYPING 1. A model or component is modeled on a Computer-Aided Design/ Computer- Aided Manufacturing (CAD/CAM) system. The model which represents the physical part to be built must be represented as closed surfaces which unambiguously define an enclosed volume. This means that the data must specify the inside, outside and boundary of the model This requirement will become redundant if the modeling technique used is solid modeling. This is by virtue of the technique used, as a valid solid model will automatically be an enclosed volume. 2. The solid or surface model to be built is next converted into a format dubbed the “STL” (STereoLithography) file format which originates from 3D Systems. The STL file format approximates the surfaces of the model by polygons. Highly curved surfaces must employ many polygons, which means that STL files for curved parts can be very large. However, there are some rapid prototyping systems which also accept IGES (Initial Graphics Exchange Specifications) data, provided it is of the correct “flavor”. 3. A computer program analyzes a STL file that defines the model to be fabricated and “slices” the model into cross sections. The cross sections are systematically recreated through the solidification of either liquids or powders and then combined to form a 3D model.
  • 23. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 23 RP WHEEL
  • 24. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 24
  • 25. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 25 Definition: 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. OR Definition: Additive manufacturing (AM) is an additive process of making a three-dimensional solid object of virtually any shape from a digital model, where materials are applied in successive layers under computer control.
  • 26. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 26
  • 27. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 27
  • 28. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 28
  • 29. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 29
  • 30. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 30 AM Evolution (History of AM) ● In the 60s Herbert Voelcker had thoughts of the possibilities of using computer aided machine control to run machines that build parts from CAD geometry. ● In the 70s he developed the mathematics to describe 3D aspects that resulted in the first algorithms for solid modeling. ● In the 80s Carl Deckard came up with the idea of layer-based manufacturing. In 1986 Charles hull, of ultra violet products, Inc. Patented this technology, which is now known as stereolithographic. Later on, Charles hull formed 3d systems, Inc. and commercialized this technology. In the years between 1988, when chuck hull's stereolithographic was first made available for public purchase, ● In 1989, Scott Crump patented the FDM (Fused deposition modeling) process, forming the Stratasys Company. ● In 1989 a group from MIT patented the 3D Printing (3DP) process. These processes from 1989 are heavily used today, with FDM variants currently being the most successful. ● Sanders developed ink jet technology process in 1994
  • 31. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 31 Clay pot making
  • 32. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 32
  • 33. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 33 Need for Additive Manufacturing As additive manufacturing evolves, optimizing designs for the technology is becoming ever-more important to unlocking the full potential of the technology. . There are mainly 6 reasons why we need to go for the design for additive manufacturing, they are: 1. Create parts with greater complexity 2. Minimal material waste 3. Simplified assembly 4. Material innovation 5. Cost-effective customization 6. Minimum support structures
  • 34. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 34
  • 35. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 35
  • 36. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 36
  • 37. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 37 AM v/s CNC
  • 38. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 38 Difference between AM & CNC machining process • An important difference between additive manufacturing technology and CNC machining process is that a prototype or model is. obtained by layer by layer addition process as opposed to removing material from a 'block'.
  • 39. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 39 Impact of AM Since the emergence of these technologies and companies, the AM industry has been constantly expanding, growing, and advancing with much enthusiasm. With many industries seeing the lucrative value and abilities of AM, the market has been expanding very quickly. Many new types of RP and AM methods have been created since these original pioneers first started developing the technology. Some new technology has been novel and some just variations of the past types. There has also been a lot of development in the materials that can be used as well as research into making their properties optimal for end use.
  • 40. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 40
  • 41. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 41 Steps in AM Process
  • 42. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 42
  • 43. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 43 • The limitation here in STL is only geometry information is stored in files while all other information that a cad model can contain is eliminated such as unit, color, material, etc. which plays a critical role in the functionality of the built part and effects finished parts
  • 44. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 44 • Once a correct STL file is available, a series of steps is required to transfer the information to start the build. The needed information varies, depending on the technology but in general, these steps start with repairing any errors within the STL file such as gaps between surface triangle facets, inverted normal where the "wrong side" of a triangle facet is identified as the interior of the part. • Series of steps is carried out to correct possible errors in the model file. • These errors can include missing triangles, inverted or double triangles, transverse triangles, open edges and contours, and shells. Each type of error can cause issues in the building process or result in incorrect parts and geometries. • Once the errors have been repaired, proper orientation of the 3d model with respect to the build platform is- decided. Following the orientation, the geometry, density, geometry of support structures are decided and generated in 3d model space and assigned to the part model
  • 45. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 45 • Machine preparation can roughly be divided into two groups of tasks such as machine hardware set up and process control. • 1) Machine hardware setup: Hardware setup entails cleaning of build chamber from the previous build, loading of powder material, a routine check of all critical build settings and process controls such as gas pressure, flow rate, oxygen sensors, etc. • 2) Process control; The tasks in the, process control group allow an additive manufacturing system • To accept and process the build files • Start the build • Interrupt the build at any given time if desired or required, • Preparing the machine for finished part extraction, • Unloading of material.
  • 46. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 46 • In this step slicer program is used to divide the models into layers in the build direction based on the desired layer thickness. • Ideally, the layer thickness would be slightly larger than the mean diameter of powder to achieve high coupling of laser energy input into the absorption, heating, and melting of powder. • Parameters which determine an amount of energy incident onto the powder bed per unit time, are energy input, beam power, scan speed, and focus move. • Once the slice information is generated, it is transferred into the interface program that runs on am systems. • The interface program serves as the interface between information of the build and machine controls that carry out the actual build process.
  • 47. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 47
  • 48. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 48
  • 49. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 49
  • 50. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 50 Post processing techniques
  • 51. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 51
  • 52. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 52
  • 53. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 53
  • 54. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 54
  • 55. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 55
  • 56. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 56
  • 57. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 57
  • 58. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 58
  • 59. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 59 Advantages of AM: 1. Increased design freedom versus conventional casting and machining 2. Light weight structures, made possible either by the use of lattice design or by designing parts where material is only where it needs to be, without other constraints 3. New functions such as complex internal channels or several parts built in one 4. Speed: one can do complex parts within hours, with limited human resources. The only machine operator is needed for loading the data and powder material, start the process and finally for the finishing. During the manufacturing process no operator is needed. 5. Customization: 3D printing processes allow for mass customization, personalize products according to individual needs and requirements. 6. Sustainable / environmentally friendly: It provides environmental efficiencies in terms of the manufacturing process by utilizing upto 90% of standard materials, and therefore creating less waste.
  • 60. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 60 7. No tools needed, unlike other conventional metallurgy processes which require molds and metal forming or removal tools 8. Short production cycle time: complex parts can be produced layer by layer in a few hours in additive machines. The total cycle time including post processing usually amounts to a few days or weeks and it is usually much shorter than conventional metallurgy processes which often require production cycles of several months. The process is recommended for he production of parts in small series. 9. No storage cost: since 3D printer can print products as and when needed, and does not cost more than mass manufacturing, no expense on storage of goods is required. 10. Increase employment opportunities: Widespread use of 3D printing technology will increase the demand for designers and technicians to operate 3D printers and create blueprints for products.
  • 61. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 61 Limitations ➢ Production series: the AM processes are generally suitable for unitary or small series and is not relevant for mass production. But progresses are made to increase machine productivity and thus the production of larger series. For small sized parts, series up to 25000 parts/year are already possible. ➢ Support material removal: when production volumes are small, the removal of support material is usually not a big issue. When the volumes are high, it becomes an important consideration. ➢ Limitations of raw material: in traditional manufacturing, there are a wide range of materials wherein an additive manufacturing technology-can work with only a few. More research is required to devise methods to enable 3d printed products to be more durable and robust. ➢ Good skills are required for application design and to set process parameters ➢ Material cost: cost of most materials of additive systems is greater than that of those used for traditional manufacturing
  • 62. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 62 .Material properties: a limited choice of materials is available: Actually, materials and their properties (e.g., tensile property, tensile strength, yield strength, and fatigue) have not been fully characterized. Also, in terms of surface quality, even the best RM processes need perhaps secondary machining and polishing to reach acceptable tolerance and surface finish. Limitations of size: 3d printing technology is currently limited by size constraints. Very large objects are still not feasible when built using 3d printers. Cost of printers: The cost of a 3d printer is high
  • 63. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 63 Classification of AM according to ASTM
  • 64. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 64
  • 65. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 65 Additive Manufacturing Technology in product development • The technology of additive manufacturing/3D printing is divided in two main application levels: • Rapid prototyping • Rapid manufacturing.
  • 66. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 66
  • 67. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 67 • Rapid prototyping again is subdivided into – solid imaging or concept modeling, – functional prototyping. Solid imaging or concept modeling: If a rapid prototyping part is made mainly for 3D visualization, it is called a solid image, a concept model, a mock-up, or even a rapid mock-up. If a part has a single or some of the functionalities of the latter product, it can be used to verify this aspect of the engineering design. Consequently it is called a functional prototype
  • 68. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 68
  • 69. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 69 Direct Manufacturing Direct Manufacturing leads to final parts that directly come from the AM process. It is not important that the available materials show exactly the same physical properties as the materials used within traditional fabrication processes.
  • 70. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 70
  • 71. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 71
  • 72. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 72
  • 73. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 73
  • 74. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 74
  • 75. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 75
  • 76. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 76
  • 77. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 77
  • 78. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 78
  • 79. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 79 Two Types of Rapid Tooling: Direct vs. Indirect
  • 80. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 80 Additive Manufacturing Materials • The main classes of materials used in 3D printing today are – Polymers – Metals – Composites – Ceramics – Sand – Wax
  • 81. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 81 • Polymers • The first 3D printing process to be developed, stereolithography, is a form of vat polymerization that cures resin to build polymer parts. Polymers are still a widely used class of 3D printed materials today, but have evolved far beyond early, brittle materials • ABS (Acrylonitrile butadiene styrene) • PLA (polylactide), including soft PLA • PC (polycarbonate) • Polyamide (Nylon) • Nylon 12 (Tensile strength 45 Mpa) • Glass filled nylon (12.48 Mpa) • Epoxy resin • Wax • Photopolymer resins
  • 82. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 82 • Metals • On the metals side, the most commonly 3D printed materials include aluminum, titanium, stainless steel, Inconel and cobalt chrome. • Copper has historically been difficult to 3D print with laser-based systems, but innovations such as blue-light lasers make this possible; reflective metals like this may be easier to print using other methods such as binder jetting. An alloy suitable for one metal 3D printing method may not be appropriate for all such methods. • Metals for 3D printing are generally provided in wire or powder formats, but can also be mixed with other materials. Newer “bound metal deposition” (BMD) systems apply filament or rods consisting of metal powder embedded in polymer to build “green” parts that then achieve their final dimensions and metal properties through firing in an oven, similar to metal injection molding (MIM).
  • 83. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 83 • Composites Composites that combine different types of materials are also gaining ground in 3D printing. The composite might be created during the 3D printing process, or that process might begin with a material that already includes an additive. Polymers reinforced with chopped carbon and glass fibers are being used for everything from short-run injection molds to composite layup tools to end-use parts, offering an option in between neat plastic and more costly metals. Some 3D printers offer the ability to lay continuous fiber reinforcement simultaneous or interspersed with the 3D printed form; others utilize sheets of reinforcing material fused with layers of polymer. Polymer composites like this can be made strong enough to be an alternative to metal in some cases, often with significant weight savings.
  • 84. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 84 • Ceramics • Ceramics have low absorption and are difficult to print with laser- based systems. However, solutions relying on extrusion, material jetting and photopolymerization have been developed. • Sand • Even sand can be 3D printed through binder jetting to selectively “glue” the grains together, a technique that is quickly advancing for both prototype and production foundry molds as well as vacuum- form
  • 85. DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.in JSSSTU R L J I T 85 Important Questions 1) Define prototype and discuss its types. 2) Define RP and discuss its types. 3) Define AM .what are the advantages, disadvantages and its applications. 4) Discuss the Evolution of AM and its classification . 5) Explain AM Process. 6) What are the postprocessing techniques used in AM and explain. 7) What are the difference between Additive and Subtractive manufacturing, 8) What are the difference between CNC and AM. 9) Discuss the AM technology used in Product development. 10) Write a note on materials used in AM.