ADDITIVE MANUFACTURING

Additive manufacturing uses data computer-aided-design (CAD) software or 3D object scanners to direct
hardware to deposit material, layer upon layer, in precise geometric shapes. As its name implies, additive
manufacturing adds material to create an object. By contrast, when you create an object by traditional means,
it is often necessary to remove material through milling, machining, carving, shaping or other means.
The term “additive manufacturing” references technologies that grow three-dimensional objects one superfine
layer at a time. Each successive layer bonds to the preceding layer of melted or partially melted material. It is
possible to use different substances for layering material, including metal powder, thermoplastics, ceramics,
composites, glass and even edibles like chocolate.
Objects are digitally defined by computer-aided-design (CAD) software that is used to create .stl files that
essentially "slice" the object into ultra-thin layers. This information guides the path of a nozzle or print head
as it precisely deposits material upon the preceding layer. Or, a laser or electron beam selectively melts or
partially melts in a bed of powdered material. As materials cool or are cured, they fuse together to form a
three-dimensional object. The journey from .stl file to 3D object is revolutionizing manufacturing. Gone are
the intermediary steps, like the creation of molds or dies, that cost time and money.
The current categories of additive manufacturing processes are:
1. Powder Bed Fusion
2. Vat Photopolymerization
3. Binder Jetting
4. Directed Energy Deposition
5. Material Jetting
6. Sheet Lamination
7. Material Extrusion
1. Powder Bed Fusion
Powder bed fusion (PBF) is a process common to a variety of popular additive printing techniques. As the
name suggests, PBF involves melting powder to a sufficient degree for the particles to fuse together. Particles
are either “sintered” (partially melted) or fully melted in various PBF processes. Thermal energy in the form
of a laser, beams of electrons or a heated print head partially or fully melt plastic or metal powder. An ultrathin
layer of material is spread by a roller or blade over the preceding layer. The powder is fed from a reservoir
beneath or next to a build platform that lowers to accommodate each successive layer of powder. At the
conclusion of the additive process, the unfused powder is blown or blasted away.
Applications
Powder bed fusion is ideal for almost all types of end manufacturing, allowing for the easy design and build
of complex geometries. Parts typically possess high strength and stiffness with a large range of post-processing
methods available.
2. Vat Photopolymerization
Vat photopolymerization differs from many additive manufacturing processes in that it begins with the use of
a liquid rather than a powder or a filament. Additive printing techniques vary although they all use
photopolymer resins -- often tough, transparent and castable materials.
Stereolithography (SLA) is a vat photopolymerization method that dates back to the 1980s. It is one of the
earliest 3D printing processes actively used today. SLA makes use of a build platform in a tank of liquid
polymer. It is a light-activated, not a heat-activated process. Resin solidifies as the laser maps each layer. After
the interaction between laser light and photopolymer creates an object layer, the platform rises, and more
liquid resin gathers immediately below the object. UV light cures each layer.
Applications
Vat photo-polymerization is excellent at producing parts with fine detail and smooth surfaces. Ideal for
jewelry, medical applications and low-run injection molds.
3. Directed Energy Deposition
Directed energy deposition (DED), (also called direct metal deposition or metal deposition), utilizes highly
focused thermal energy delivered via laser, electron beam or plasma arc to melt and fuse material jetted into
the heated chamber from either powdered metal or wire filament. The additive process is most commonly
used with metal, although some DED systems can be used ceramic powder or polymers.
Applications
Exclusively used in metal additive manufacturing, this process is ideal for repairing or adding material to
existing components.
4. Material Jetting
Material jetting is an additive manufacturing process that uses drop-on-demand (DOD) technology. Like a 2D
inkjet printer, tiny nozzles dispense tiny droplets of a waxy photopolymer, layer by layer. UV light cures and
hardens the droplets before the next layer is created. Since this additive technology relies heavily on support
structures, a second series of nozzles dispenses a dissolvable polymer that supports the object as it is printed.
When printing is complete, the support material is dissolved away. Material jetting produces patterns used in
lost-wax casting, investment casting and mold making.
Applications
Ideal for realistic prototypes with high detail, high accuracy and a smooth finish. Material jetting allows for
multiple colors and materials in a single printout.
5. Binder Jetting
The binder jetting process is similar to material jetting, although it employs powdered material and a binding
agent. Nozzles on these 3D printers deposit tiny droplets of a binder on an ultrafine layer of powdered metal,
ceramic or glass. Multiple layers result from the powder bed moving downward after each layer is created.
Applications
Ideal for aesthetic applications like architectural and furniture design models. It is generally not used in
functional applications due to its brittle nature.
6. Sheet Lamination
Sheet lamination is an additive manufacturing process in which ultra-thin layers of solid material are bonded
by alternating layers of adhesive. It is possible to use a variety of materials in this additive process called
laminated object manufacturing (LOM).
Applications
Best for non-functional models, benefits include speed, low cost, ease of material handling
7. Material Extrusion
Fused deposition modeling (FDM), or fused filament fabrication (FFF), is perhaps the most well-known
additive manufacturing process. When the general public hears “3D printing,” this is the process they often
think of. A thermoplastic filament is extruded through a heated nozzle and onto the build platform. The
material solidifies as it cools, although not until it fuses to adjacent layers. FDM uses a wide variety of
thermoplastic filaments, including ABS, PLA, nylon, PC , ULTEM and more complex filaments like those
that are metal-filled and wood-filled.
Because the process is fast and inexpensive, it is often used to produce prototypes. Although dimensional
accuracy was a concern in the past, some modern industrial FDM machines produce functional prototypes.
Applications
Quick and cost effective, FDM is often the go-to method for producing non-functional prototypes or rapid
prototyping where several iterations are needed.
3D PRINTING
3D printing is any of various processes in which material is joined or solidified under computer control to
create a three-dimensional object, with material being added together (such as liquid molecules or powder
grains being fused together). 3D printing is used in both rapid prototyping and additive manufacturing. Objects
can be of almost any shape or geometry and typically are produced using digital model data from a 3D model.
There are many different technologies, used in the 3D printing process. The most common by number of users
being fused deposit modeling (FDM).
RAPID PROTOTYPING
Rapid Prototyping (RP) can be defined as a group of techniques used to quickly fabricate a scale model of a
part or assembly using three-dimensional computer aided design (CAD) data.
What is commonly considered to be the first RP technique, Stereolithography, was developed by 3D Systems
of Valencia, CA, USA. The company was founded in 1986, and since then, a number of different RP techniques
have become available.
Rapid Prototyping has also been referred to as solid free-form manufacturing, computer automated
manufacturing, and layered manufacturing. RP has obvious use as a vehicle for visualization. In addition, RP
models can be used for testing, such as when an airfoil shape is put into a wind tunnel.
There is a multitude of experimental RP methodologies either in development or used by small groups of
individuals. This section will focus on RP techniques that are currently commercially available, including
Stereolithography (SLA), Selective Laser Sintering (SLS), Laminated Object Manufacturing (LOM), Fused
Deposition Modeling (FDM) and Ink Jet printing techniques.
The reasons of Rapid Prototyping are
 To increase effective communication.
 To decrease development time.
 To decrease costly mistakes.
 To minimize sustaining engineering changes.
 To extend product lifetime by adding necessary features and eliminating redundant features early in
the design.