UNIT – I INTRODUCTION

Need, Fundamentals of Additive and digital Manufacturing, Advantages and

Applications, Comparison of Additive Manufacturing with traditional
Manufacturing, Additive Manufacturing (AM) process chain: 3D model,
converting into STL file, transfer to system, checking, machine setup and
building, Post process. Classification of AM process. Materials used in
Additive Manufacturing Processes, Need for AM in product development
and rapid tooling.

The term „additive manufacturing‟ was given by the ASTM F42 committee.
• Technology that can make anything.
• Eliminates many constraints imposed by conventional manufacturing
• Leads to more market opportunities.
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. The term ‘3D printing’ is
increasingly used as a synonym for AM.
Additive manufacturing, also known as 3D printing, rapid prototyping or freeform
fabrication, is „the process of joining materials to make objects from 3D model data, usually
layer upon layer, as opposed to subtractive manufacturing methodologies‟ such as machining.
The use of Additive Manufacturing (AM) with metal powders is a new and growing
industry sector with many of its leading companies
Additive manufacturing now enables both a design and industrial revolution, in various
industrial sectors such as aerospace, energy, automotive, medical, tooling and consumer goods.
AM evolution
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 And while there
are several people that have pioneered the Rapid Prototyping technology, the industry generally
gives credit to Charles Hull.
Additive manufacturing first emerged in 1987 with stereolithography (SL) from 3D
Systems, a process that solidifies thin layers of ultraviolet (UV) light‐sensitive liquid polymer
using a laser. The SLA‐1, the first commercially available AM system in the world, was the
precursor of the once popular SLA 250 machine. (SLA stands for StereoLithography
Apparatus.) The Viper SLA product from 3D Systems replaced the SLA 250 many years ago.

OME1902 Basics of 3D Printing and Additive Manufacturing M.Rajkumar [MECH]

 1988-1994
1994
1995
2001 AM for automotive
2004 aerospace (polyme.rs)
2005 medical (polymer jiss and suides)
2009 medical implants (metals)
2011 aerospace (metals)
2013-2016 nano-manufacturing
2013-2017 architecture
2013-2018 biomedical implants
2013-2022 in situ bio-manufacturin
2013-2032 full body organs

Some of the advantages of Additive manufacturing are:

1. Reduces material wastage as compared to traditional subtractive process wher material is
removed from the stock to get the desired product dimensions
2. Reduces the number of operations as compared to traditional product manufacturing
3. Reduces the skill required by the operator for multiple machine operations
4. Reduces the time of product development as compared to traditional processes.
Hence, the name of AM was initially rapid prototyping which is even today used in some
industrial segments for AM.
5. Reduces the cost of raw materials as the process has minimum or zero wastage
6. Provides designers freedom to design parts that were not possible to manufacture in
traditional manufacturing processes.
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. Net shape process meaning less raw material consumption, up to 25 times less versus
machining, important in the case of expensive or difficult to machine alloys. The net shape
capability helps creating complex parts in one step only thus reducing the number of
assembly operations such as welding, brazing.
5. No tools needed, unlike other conventional metallurgy processes which require molds and
metal forming or removal tools
6. 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.

OME1902 Basics of 3D Printing and Additive Manufacturing M.Rajkumar [MECH]

Applications of AM process
Additive Manufacturing in the recent years has gained lot of traction due to extensive media
coverage and development in scientific field. The rapid development of the field has made AM
to be applied in various processes and fields. Today AM is part of the entire engineering
industry and is considered to be the next disruptive technology the industry will experience.
Applications in Civil Engineering field
- In construction of bridges
- Building 3D printed houses
- Small size building aids for workers and labourers
- Building plans for easy understanding
- Building material to optimize space
Applications in Electrical and Electronics field
- Building of printed microelectronics
- Enclosures to Printed Circuit Boards
- Printing of fixtures for accommodating motors and sensors
- Use of printed robotics for evaluation
- Printed electronics and electrical devices
- Manufacture of printed boards, panels
- Manufacture of printed electronic elements, electrical ducts, hoses and enclosures
- Building robotic arms, prototypes
- Building enclosures for PCBs and supporting structures
Applications in Mechanical Engineering field
- Used for prototyping ideas in the field of new mechanical parts and appliances.
- Development of manufacturing fixtures
- Hybrid manufacturing application in CNC s and Flexible manufacturing systems
- Automotive parts and material handling systems
- Next generation robots and grippers
- Dies and moulds in injection moulding applications
Applications in Medical industry
- Quick development of equipment
- Product prototypes for operating electronics
- Prototypes of human parts used for training
- Development of aids for differently abled people

OME1902 Basics of 3D Printing and Additive Manufacturing M.Rajkumar [MECH]

 - Manufacturing of artificial bones in replacement of hip and knee joints and implants
Applications in Biotechnology
- Development of 3D printed organs using enhanced gene studies
- Development of molecular level assembly studies
Distinction between AM & CNC machining
CNC machining and additive manufacturings are both computer-controlled solutions to
making products out of a given material. They’re both machines at the forefront of building
technology safely and efficiently.
As machinists and engineers want to build a prototype, a part or a custom product, they
can turn to one of these machines to do the job for them. As long as the machines have the
design, you don’t have to worry about human error because the machines are automated. While
this doesn’t mean issues don’t arise, there’s more consistency with production and less chance
of injury.
There is some overlap with these two manufacturing methods. Some CNC machines
can use STL and OBJ files, which 3D printers also accept.
CNC machinery is older than 3D printing and still has a stronger foothold in
manufacturing. The form started in the 1940s and had molded to fit into the industry up to the
present. 3D printing came along in 1986. It’s still relatively new and evolving to be more
accessible and versatile. 3D printing can help in some areas of prototyping, but it’s not a
replacement tool for CNC machining.
3D printers are typically more efficient than traditional manufacturing. The printer uses the
materials that make up the item it’s creating, whereas traditional manufacturing methods such
as CNC Machining require more materials for the mold to work. On average, 3D printers
produce less waste than traditional manufacturing methods.
However, when production is large-scale, traditional manufacturing methods have a
distinct advantage. Assembly lines are faster than a 3D printer in mass production because
printers build layer by layer. In the hours that it could take to 3D print a product, an assembly
line could have mass- produced hundreds of the same product.
3D printers can manipulate different materials such as plastics, metals and polymers. However:
1. Not all 3D printers can use these materials. It takes separate machines for each material.
2. 3D printers cannot work with every material that traditional manufacturers use due to
high melting points.
3. Some projects might not be able to consider using 3D printers if they require specific
materials that are incompatible with the printers.
3D Printing vs. Traditional Manufacturing
CNC machining starts with a block of material and shapes it with a rotating tool. Following the
program, it carves away excess until you have the finished product. This is the subtractive
method because it’s taking away material.
3D printing layers on material in the additive method that builds your design. Both ways have
pros and cons in terms of durability, precision and use of materials.

OME1902 Basics of 3D Printing and Additive Manufacturing M.Rajkumar [MECH]

AM process chain
A series of steps goes into the process chain required to generate a useful physical part from
the concept of the same part using additive manufacturing processes. Depending on the
technology and, at times the machines and components, the process chain is mainly made up
of six steps:
1. Generation of CAD model of the design;
a. The process of producing a 3D CAD model from an idea in the designer‟s mind
can take on many forms, but all requires CAD software programs. There are a
large number of CAD programs with different modeling principles, capabilities,
accessibilities, and cost. Some examples includes Autodesk Inventor,
Solidworks, Creo, NX, etc.
b. Once a 3D CAD model is produced, the steps in the AM process chain can take
place. Though the process chain typically progresses in one direction that starts
with CAD modeling and ends with a finished part or prototype, it is often an
iterative process where changes to the CAD model and design are made to
reflect feedback from each steps of the process chain.
2. Conversion of CAD model into AM machine acceptable format;
a. Almost all AM technology available today uses the STereoLithography (STL)
file format. The STL format of a 3D CAD model captures all surfaces of the 3D
model by means of stitching triangles of various sizes on its surfaces. The spatial
locations of the vertices of each triangle and the vectors normal to each triangle,
when combined, these features allow AM pre-process programs to determine
the spatial locations of surfaces of the part in a build envelope, and on which
side of the surface is the interior of the part.
b. STL format has been consider the de facto standard, it has limitations intrinsic
to the fact that only geometry information is stored in these files while all other
information that a CAD model can contain is eliminated. Information such as
unit, color, material, etc. can play critical role in the functionality of the built
part is lost through the file translation process.
3. CAD model preparation;
a. Once a correct STL file is available, a series of steps is required to generate the
information an AM system needs to start the build process. The needed
information varies, depending on the technology but in general these steps start
with repairing any errors within the STL file. Typical errors can be gaps
between surface triangle facets, inverted normal where the “wrong side” of a
triangle facet is identified as the interior of the part.
b. Once the errors have been repaired, a proper orientation of the 3D model with
respect to the build platform/envelope is then 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. The process
then progresses to slicing the 3D model defined by the STL as well the support
structure into a given number of layers of a desired height each representing a
slice of the part and support models. Within each slice the cross-sectional
geometry is kept constant.
4. Machine setup;
a. Following software preparation steps in the AM process chain, machine
preparation is the next step before a build a can start. Machine preparation can
roughly be divided into two groups of tasks: machine hardware setup, and
process control.

OME1902 Basics of 3D Printing and Additive Manufacturing M.Rajkumar [MECH]

 b. Hardware setup entails cleaning of build chamber from 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. Details of how
each task in this group is carried out can vary from one system to another, but
overall once the machine hardware setup is complete, the AM system is ready
to accept the build files (slices generated from previous step) and start the build.
5. Part removal;
a. The build time of the powder bed process depends on a number of factors. Of
them, the height of the entire build has the largest effect on the total time. It can
take anywhere from minutes to days. Nevertheless, once the build completes,
the laser metal powder bed technology allows for immediate unpacking of build
chamber and retrieval of finished part, because the process does not maintain
the build platform at elevated temperatures (as opposed to laser powder bed for
polymers and electron beam-based powder bed processes).
b. The unpacking process typically involves raising the platform in the build
chamber and removing loose powder at the same time. The loose powder from
one process can be re-used and has to go through a series of sieving steps to
remove contaminates and unwanted particulates.
6. Post-processing.
a. Depending on AM technology used to create the part, the purpose, and
requirements of the finished part, the post-fabrication processes can vary in a
wide range. It can require anything from no post process to several additional
steps of processing to change the surface, dimensions, and/or material properties
of the built part.
b. Ex: In metal powder bed AM systems, the minimum required processing is
removal of built part from build plate and the removal of support structures from
the built part. Removal of support structures can be as simple as manually
breaking the supports from the surface of the part, but it can also be a process
that utilizes CNC tools to not only remove the support, but also to achieve
desired surface finish and/or dimension tolerance.
Additive Manufacturing in general follows few steps by which the manufacturing process
can be described. These steps are mostly common for all types of additive manufacturing
processes and are followed by most of the 3D printers/AM machines.
Steps in AM
The various steps in AM are as follows:
Step 1: Computer Aided Design and Drawing
Step 2: Conversion of the CAD part to STL(*.stl) files
Step 3: Slicing of the STL files into layers using standard slicing software
Step 4: Create a G-code which is understood by the machine
Step 5: Setting up the machine
Step 6: Layer by layer printing of the job
Step 7: Removal of the part
Step 8: Post processing to get the final product as visualized

OME1902 Basics of 3D Printing and Additive Manufacturing M.Rajkumar [MECH]

 • Idea generated
•CAD Drawings to define the idea into a dimensional part

•CAD to5TL
• Use of softwares to convert drawing into Standard Tessallation Language file

• SIicing the STL file

•using standard softwares and the surface finish requirement the part is sliced into corresponding layers

• Create Gcode
•based on the sliced data a software converts the sliced parts Into aGeode which is understood by machine

•Selling up the machine by intializing the machine and switching on the machine for printing

• Printing of the part layer by layer is carried out for obtaining the requisite part

• Removal of the part after printing and cleaning of the part and removal of support structures of part

• Post processing
• After removal of the completed part the part can be post processed to remove unnecessary material.

Additive Manufacturing Process Chain

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Step 1: CAD
CAD models that fully describe the external geometry are required for all AM parts. Any
professional CAD solid modelling software can be used to create this, but the final product

OME1902 Basics of 3D Printing and Additive Manufacturing M.Rajkumar [MECH]

must be a 3D solid or surface model. To create such an image, reverse engineering equipment
(for example, laser and optical scanning) can also be used.
Step 2: Conversion to STL
Upon completion of the digital model, the STL (Standard Tessellation Language) file format
must be used to create the stereolithography. Nearly every CAD system supports this format,
which is how AM machines communicate. The STL file serves as the basis for calculating the
slices of the model.
Step 3: Transfer to Machine
In the third step, the STL file is transmitted to the AM machine. As a result of this step, it is
possible to adjust the build so that it is positioned and sized correctly. A computer controls the
AM machine. The AM machine is controlled by the computer, that computer only generates
the required instruction in the form of G-codes and M-codes based on the given process
parameters. It generates instructions automatically, if any correction is needed for the
betterment of the part to be built it can be corrected.
Step 4: Setup
Before the building starts, the equipment has to be set up. The settings can constitute power,
speed, layer thickness, and other several parameters related to material and process constraints,
etc.
Step 5: Build
The fifth step is the actual building of the CAD model, melting layer by layer. This process can
be semi or fully automated but some online monitoring is often conducted, so that the machine
does not run out of material or that some software error occurs.
Step 6: Part Removal
Once the part is manufactured it has to be removed from the process, which is normally done
manually. This may require interaction with the machine, which may have safety interlocks to
ensure, for example, that the operating temperatures are sufficiently low or that there are no
actively moving parts.
Step 7: Post-processing
After the build, the part might need some post-processing before it is completely finished. Of
course, depending on the material and AM process used, some parts might need machining,
cleaning, polishing, removal of support structures, hot isostatic pressing (HIP), and heat
treatments.
Step 8: Application
At this stage, the part can be ready for use. Nevertheless, it could also need some additional
treatments, like painting, or assembling with other components before it is fully usable. For
example, they may require priming and painting to give an acceptable surface texture and
finish. Treatments may be laborious and lengthy if the finishing requirements are very
demanding. They may also be required to be assembled with other mechanical or electronic
components to form a final model or product.

OME1902 Basics of 3D Printing and Additive Manufacturing M.Rajkumar [MECH]

Classification of AM Processes
There are numerous ways to classify AM technologies. A popular approach is to
classify according to baseline technology, like whether the process uses lasers, printer
technology, extrusion technology, etc. Another approach is to collect processes together
according to the type of raw material input. The problem with these classification methods is
that some processes get lumped together in what seems to be odd combinations (like Selective
Laser Sintering (SLS) being grouped together with 3D Printing) or that some processes that
may appear to produce similar results end up being separated (like Stereolithography and
material jetting with photopolymers). It is probably inappropriate, therefore, to use a single
classification approach.
An excellent and comprehensive classification method is described by Pham, which uses a two-
dimensional classification method as shown in Fig.

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Types of AM Process:
Additive manufacturing can be classified into many types. The processes are elaborate and
developing at a very fast pace. However, we shall restrict the study in this to two important and
low cost processing techniques which are fused filament fabrication and Digital Light
Processing techniques.
Classification of AM process
a. Fused Filament Fabrication
b. Stereolithography / Digital Light Processing
c. Powder bed fusion
d. Sheet Lamination techniques
e. Solid Ground Curing

OME1902 Basics of 3D Printing and Additive Manufacturing M.Rajkumar [MECH]

f. Material Jetting Technology
g. Direct Write
h. Direct Energy Deposition

Additive
manufacturing
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Liquid material Solid materials
material

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process Extrusion Liquid Lamination
Joining process
process plymerisation process

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Fused
Photo-masking
deposition Laser process
process
modelling

Materials used in AM:

There are various materials that are being used in Additive Manufacturing process. The
materials that are used in this technology are as follows:
1. Polymers
2. Metals & Alloys
3. Composites
4. Ceramics
5. Elastomers
Polymers: Many long chain polymers are used in this process ranging from epoxies to
Acrylates and polyamides. The use of epoxy shows a lot of variations but a stable material as
compared to acryaltes. A mixture of acrylate and epoxies are an ideal candidate for application
in prototypes. Acrylo-nitrile Butadiene Styrene (ABS) is used in additive manufacturing
applications. Poly Lactic Acid and Polycarboneates (PC) are also used in 3D printers. There
are a lot of research possibilities in application of new polymers in this field which is evolving
at a very fast rate.

OME1902 Basics of 3D Printing and Additive Manufacturing M.Rajkumar [MECH]

Metals: Most of the metals like Aluminium, Mild steel and structural materials can be
manufactured using layer by layer process. This manufacturing process occurs by partially
melting or bringing the metal powders to a phase transition from solid to liquid and then
solidification using lasers or electron beams. Hence the materials are expected to be in powder
or in the form of wires in geometry for easy handling and processing. Researchers like GE
Additive have worked on various metals such as Aluminium and its alloys, Cobalt and Chrome
alloys, Titanium alloys, Nickel-based alloys, stainless steels. There materials are used on
production of aerospace and automotive parts that are traditionally manufactured using
multiple setups and larger lead times.
Composites: ULTEM 1010 which is a trademark product of Stratasys has been extensively
used in Fiber reinforced composites in conjunction with hand layup process and has shown
good amount of results in manufacturing of aero parts that require lightweight honeycomb
structure. Manufacturing of wood and textiles are examples of printing natural fibre composites
and synthetic composites using nylon and other materials. A new 3D printer also prints Kevlar
as a composite into three dimensional shapes. Some filaments like willow flex provides natural
fiber printing commercially.
Ceramics: Various materials in ceramics are being developed commercially and in laboratories
for the use of ceramics in manufacturing of high temperature parts. 3d Ceram is a company
that has developed printers capable of printing Zirconia, Alumina, hydroxiapatite/TCP, Silicon
Nitride, Zirconsilica and other silica materials. WASP has developed 3D printing of clay parts
in 3D printers using extrusion based systems. Using binder jetting clay is printed and then
sintered at high temperatures to achieve surface integrity. Form labs have worked to release
the ceramic resins that are ideal for photo polymerization.
Elastomers: These are materials which behave as synthetic rubber and polymer based
materials which gives its name elastomers. They are very useful in FMCG sector as it gives
good elasticity and compressive strength as rubber like materials. Elastomers can replace many
human like artifacts and work as an external skin on certain materials. Liquid
Pilydimethylsiloxane (PDMS) is used for printing in a method called EGO from Carniege
Mellon University(CMU) which can be used in medical devices and wearable.
Impact of Additive Manufacturing in Product Development
The manufacturing product development process can be complex, especially without
expert guidance. It requires a number of phases, a great deal of research, and hands-on problem
solving and iteration.
Some of the most common complications manufacturers experience while navigating
this process are timeline restrictions and costly prototypes. Additionally, even experienced
manufacturers overextend their resources—and many aren’t aware of or don’t have access to
the innovations that make product development more efficient, less wasteful, and more
affordable.
Additive manufacturing builds three-dimensional objects by adding material in layers
(as opposed to cutting or stamping them from a larger mass of material). The technology
provides endless opportunity for manufacturers. And this type of Industry 4.0 technology is top
of mind of mind for Northeast Ohio manufacturers, as more than a quarter have already
invested in it for applications like prototyping.
Additive Manufacturing Requires Less Material
Less Time = Higher Efficiency
7 Benefits of Additive Manufacturing for Product Design & Development
1. Realizing Design Concepts

OME1902 Basics of 3D Printing and Additive Manufacturing M.Rajkumar [MECH]

 2. Minimizing Design Flaws
3. Incorporating Design Changes Instantly
4. Saving Cost and Time
5. Customizing Designs
6. Fully-Managed Print Jobs
7. Potential for More Sustainable Designs
Rapid Tooling
Rapid Tooling is any method or technology that enables rapid production of parts, which will
function as a tool (primarily die or mold). In manufacturing industry, one of the most common
Rapid Tooling methods - Injection Mold Tooling is utilized as Rapid Tooling channel to
produce injection-molded parts quickly and inexpensively.
Benefits of Rapid Tooling
1. Faster Time to Market
2. Lower Cost
3. Variety of Material Grades
4. Designs and Functionality Testing
5. Process Parameter Testing
Choosing the Best Rapid Tooling Process
Although there are a lot of advantages in Rapid Tooling process, Rapid Tooling is not always
suited for all projects. One of the drawbacks of Rapid Tooling is precision. Rapid Tooling
might not be as precise as conventional tooling. However, it becomes less concern nowadays
thanks to the technology advancement in the 3D printing and CNC machining technology,
which shows great improvement in precision and accuracy.
Before starting your project, always consult with an experienced manufacturer your
requirement and expectation. Main factors that will decide whether Rapid Tooling process is
appropriate for you project are as following:
1. Project Budget
2. Product Development Timeframe
3. Part Specification & Tolerances
4. Multiple Materials to be tested?
5. Mold or Die to be used for large-scale production?
The upfront clear and well communication with manufacturer will help manufacturer determine
which process is your best option. It will save you a lot of time and fortune with relatively ease
in your project from prototyping stage to manufacturing stage.
Classification of AM processes as per ASTM
1 Binder jetting. Example: BJ3DP
2 Directed energy deposition. Examples: LENS, EBAM
3 Material extrusion. Example: FDM, FPM, PME
4 Material jetting. Examples: IJP, PJ
5 Powder bed fusion. Examples: SLS, SLM, EBM
6 Sheet lamination. Examples: UC (White 2003)
7 Vat photopolymerization. Examples: SL, DLP

OME1902 Basics of 3D Printing and Additive Manufacturing M.Rajkumar [MECH]

UNIT 2
SYLLABUS - Introduction to Reverse Engineering: Applications, Steps in reverse Engineering. Design for
additive manufacturing: CAD model preparation, Part orientation and support generation and removal, Model
slicing and software‘s – Tool path generation. File formats in AM. Data Processing and Controllers.
Reverse Engineering
Reverse engineering is defined as the process of obtaining a geometric CAD model from 3-D points acquired
by scanning/digitizing existing parts/products. The process of digitally capturing the physical entities of a
component, referred to as reverse engineering. Reverse-engineering can be used to learn how something works
and to recreate the object or to create a similar object with added enhancements. As products become more
organic in shape, designing in CAD becomes more challenging. Reverse engineering provides a solution to
this problem because the physical model is the source of information for the CAD model. Also it helps in
compress product development cycle times.
Applications of RE
Manufacturing - Automobile
Software Code
Industrial design
Jewelry design
Reproduction
Injection-molding companies need to shorten tool and die development time drastically.
By using reverse engineering, a three dimensional physical product or clay mock-up can be quickly
captured in the digital form, remodeled, and exported for rapid prototyping/tooling or rapid manufacturing
using multi-axis CNC machining techniques.
Forward Engg RE
Model to System System to Model
Specification Description
Model Original Model Copy
Design Model Analysis Model
Process of synthesis Process of analysis
Purpose of reverse engineering
 Update products
o Rebuild
 An old or outdated product
 An expensive product using cheaper or more readily available materials
 A product that uses machine parts that no longer exist
 Another company's product to learn about it
 Repair products
 Testing for errors
Steps in RE
 Collect information
 Create a model or sketch
 Begin disassembly
 Evaluate the product
 Reassemble
Why Use Reverse Engineering?
1. The original manufacturer no longer exists
2. The original manufacturer of a product no longer produces the product,
3. The original product design documentation has been lost or never existed.
4. Creating data to refurbish or manufacture a part for which there are no CAD data,
5. Some bad features of a product need to be eliminated
6. Strengthening the good features of a product based on long-term usage.
7. Analyzing the good and bad features of competitors’ products.
 8. Exploring new avenues to improve product performance and features.
9. Creating 3-D data from a model or sculpture for animation in games and movies.
10. Creating 3-D data from an individual, model or sculpture to create, scale,or reproduce artwork.
Need for Reverse Engineering
 Manufacture of service components after discontinuation of the product line.
 Redesign of an existing design which lacks adequate product data documentation
 Corrupt data file or loss of CAD design for a product
 Generation of cheaper alternate products as a substitute for monopoly products
 Competitive benchmarking of product components
Relationship to Rapid Prototyping
Most traditional manufacturing techniques use subtractive or formative processes, RP techniques build
the model, one layer at a time, from bottom to top. This additive nature provides cohesiveness with the data
types created by reverse engineering systems, as they are created in sliced intervals as well. As a result, any
model can be quickly cloned. Once the data has been successfully acquired by the reverse engineering system,
limitless design alternatives, achieved through modification or scaling of the newly-acquired CAD data, may
be fabricated into physical prototypes to achieve any of the aforementioned manufacturing objectives.

CAD Prototype
Model Part

Reverse Rapid
Engineering Prototyping
Digitization Techniques
Non-contact
Reverse Engineering Digitization Techniques
Contact
Reverse Engineering Digitization Techniques
Contact methods, the more traditional manner of collecting data that has been utilized for several years,
requires contact between the surface and a measuring device, usually a probe or stylus.
Contact methods generally measure the surface of the object using a contact probe, a highly sensitive pressure-
sensing device that is activated by any contact with an object.
The linear distances from three axes to the position of the probe are find out, thus giving the x, y, and z
coordinates of the surface.
Contact based methods of reverse engineering have been available for nearly forty years.
The first (and still the most popular) method of reverse engineering, to be introduced was the Coordinate
Measuring Machine (CMM).
A Coordinate Measuring Machine gives physical representation of a three-dimensional Cartesian coordinate
system.
The CMM measures the surface of the object using a contact probe, a highly sensitive pressure sensing device
that is activated by any contact with an object.
The linear distances from three axes to the position of the probe are ascertained, thus giving the x, y, and z
coordinates of the surface.
Types of CMM Configurations
1. Bridge Gantry type
2. Cantilever Type
3. Horizontal Arm Type
4. Articulated Arm Type
Read the book “Ali Kamrani, Emad Abouel Nasr - Rapid Prototyping_ Theory and Practice (Manufacturing
Systems Engineering Series) (2006)” Chapter – 5 (Attached in GCR)
CMM Measurement process Chapter 5- Section 5.4
Non Contact Method
Active Technique - Laser Scanning
Passive Technique -3D Photogrammetry
Medical Imaging
1. Magnetic Resonance Imaging
2. Computed Tomography
3. Ultrasound Scanning
4. Medical Image Data File
5. Three-Dimensional Reconstruction
Non-contact scanning devices
There are a variety of non-contact scanning technologies available on the market, all of which capture data
without physically interacting with the component.
Non-contact devices use lasers, optics, and CCD sensors to capture point data.
Although these devices capture large amounts of data in a relatively short space of time, there are a number
of issues related to this scanning technology.
The accuracy of non-contact scanning is still somewhat limited; tolerances as poor as +/— 0.5mm (for each
point captured) are not uncommon.
Non-contact methods typically use light, or laser beams, as the main tool for deducing surface information.
Non-contact techniques can be classified into two additional categories:
Active and
Passive techniques
Active techniques, organized into two subgroups,
structured lighting and
spot ranging
Structured lighting methods are classified according to the pattern of light that is used to illuminate
the object, such as single light beam, single stripe of light, and patterned lighting. Surface information is
determined using triangulation procedures.
Spot ranging techniques are generalized based on the source used, either optical-based or ultrasonic.
These methods involve the projection of a beam onto the object surface and the inspection of the reflected
beam using a sensor.
Both methods cast a beam onto the object surface and then inspect the reflected beam using a sensor that is
placed coaxial to the source.
The location of the source gives the two coordinate measurements of the surface point while the
analysis of the reflected beam gives the third dimension.
The third coordinate is determined either by calculating the phase difference between the incident
and reflected light or by the time taken for the light to reflect back from the surface of the part.
Passive techniques, work with ambient light, and are divided into three:
Stereo scanning,
Is accomplished by acquiring two or more images of the object from different perspectives. The
corresponding surface points on the two images are identified, and a triangulation procedure is used to
identify the location of points.
Range from texture
Were based on the fact that the further away from an object one is, the smoother its surface will
appear to be. So if the texture is known, its distance from a known viewpoint can be estimated by inspecting
the perceived texture at that distance. This method has limited accuracy and is not widely used in reverse
engineering applications.
Range from focus techniques
Are based on using the focal length of a lens to estimate the part's distance. This method is rarely
used for reverse engineering purposes.
 REVERSE
ENGINEERING
TECHNOLOGI

ACTIVE PASSIVE
TECHNIQUES TECHNIQUES

Spot Ranging
Structured Lighting Single View Multiple View

Range from Focus

Ultrasonic Systems Optical Systems

Stereo Scanning

Time ofFtight Modulation

Single Point Single Stripe Multiple Stripe.s Patterned Lighting

Grid Coded Moire Topography

Illumination

Cost Associated
 A generic cost Model:
 It is assumed that a good STL model is available and the entire evaluation starts from model
preparation.
 The total cost
Ct=Cpre+Cbuild+Cm+Cpost (1)
 Where
Cpre= Direct cost related to pre-processing
Cbuild = Machine Utilization cost for building the prototype model.
Cm =Material cost
Cpost = Post processing cost.
The pre-processing cost is determined by the following factors:
 Model positioning time: Tpos
 Support Generation Time: Tsup
 Model Slicing time: Tsli
 Tool path generation time: Tpath
 Machine Setup Time: Tsetup
 Cpre=(Tpos+Tsup+Tsli+Tpath) (Rstaff +Rcomp)+ Tsetup (Rstaff + Rmach) (2)
 Where
 Rstaff = Staffing cost ( Can be based on hourly rate)
 Rcomp=Cost related to Computing facilities and Rapid Prototyping Machine.
 Rmach=Machine utilization time.
  Machine utilization cost can be estimated based on initial machine cost after considering machine
depreciation.
Machine Utilization cost for building the prototype model
Cbuild=Tbuild.Rmach
 Material cost
Cmat=Cmat-model+Cmat-support
 Post Processing Cost
Cpost=Tpost .Rstaff +Cmisc
Where
Cmisc stands for miscellaneous costs (post curing, support removal etc.)
Build time estimation varies from process to process and it dictates the overall cost.
In case of SLA it depends on the laser spot dimension, the laser power that determines the scanning speed
and the hatching pattern. The switching time between two consecutive layers also contributes significantly
in the overall build time.
In case of SLS process, the build time mainly depends on the laser drawing speed.
In case of FDM, the overall building time for a given modeling material is usually not sensitive to part
orientation, but part orientation will largely affect the consumption of support material. Part orientation will
thus directly influence the overall building time and post processing time.
In many situations, one can produce multiple parts in a single setup. This is substantially useful for
processes such as SLA and SLS that involve substantial times while switching between layers.
In addition to part orientation, another technical issue concerns how one should pack the part in 3D in order
to achieve maximum utilization of the machine capacity.
Support Structure
Refer - https://all3dp.com/1/3d-printing-support-structures/
 UNIT3
LIQUID BASED AND SOLID BASED ADDITIVE
MANUFACTURING SYSTEMS
 CLASSIFICATION OF ADDITIVE
MANUFACTURING SYSTEM

It can categorized into 3 types

• Liquid-Based
• Solid-Based
• Powder-Based
 Liquid Based System - Stereolithography
Apparatus (SLA)
• Stereolithography (SLA) was found ed in 1986 by Charles W Hull
and Raymond S Freed and 1987 first commercial AM process was
developed
• SLA is a additive manufacturing technology for producing models,
prototypes, and patterns.
• The first developed AM technique is SLA.
• There are several models/Products available in SLA
✓ SLA 250/30A
✓ SLA 250/50
✓ SLA 250/50 HR
 Process Of SLA
• 3D systems stereolithography process creates three-dimensional
plastic objects directly from CAD data.
• The SLA process begins with vat filled with photo-curable liquid
resin and elevator table just below the surface of liquid resin.
• The operator loads 3 dimensional CAD model file into the
system.
• The translator converts CAD data into STL file.
• The control unit slices the model and support into a series of
cross-section from 0.025 mm to 0.5 mm thick.
• The computer controlled optical scanning system directs and
focuses the laser beam
• It solidifies 2 dimensional cross section corresponding to the
slice of surface of photo curable liquid resin to a depth greater
than one layer thickness.
 Process Of SLA
• The elevator table drops enough to cover the solid polymer with
another layer of liquid resin.
• A leveling wiper moves across the surface to recoat next layer of
resin on the surface.
• The laser then draws next layer.
• The process continues building the part from bottom up until
the system completes the part.
• Finally the part is raised from vat and cleaned the excess
polymer.
• The parameters are used Heat energy, layer thickness and
polymer density.
SLA- STEREOLITHOGRAPHY

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Stereolithography - SLA

Rapid Prototyping Ma nufacturing

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 Process Of SLA
• The Main components of SLA are:
✓ Control computer
✓ Control panel
✓ Laser
✓ Optical system and
✓ Process chamber
 Process Of SLA
The workstation used by SLA system known as 3D LIGHT
YEAR exploits the full power of windows NT operating system and
delivers far richer functionality then UNIX based Maestro system .

Maestro includes following softwares:

(1) 3dverify Module. This module can be accessed to confirm the
integrit y and/or provide limited repair to stereolithography (STL)
files before part building without having to return to the original
CAD software. Gaps between triangles, overlapping or redundant
triangles and incorrect normal directions are some examples of the
flaws that can be identified and corrected.
{2)View Module. This module can display the STL files and slice file
(SU) in graphical form. The viewing function is used for visual
inspection and for the orientation of these files so as to achieve
optimal building.
 Process Of SLA
(3) MERGE Module. By using MERGE, several SU files can be merged into
a group which can be used together in future process.
(4) Vista Module. This module is a powerful software tool that
automatically generates support structures for the part files. Support
structures are an integral part to successful part building, as they help to
anchor parts to the platform when the part is free floating or there is an
overhang.
(5) Part Manager Module. This software module is the first stage of
preparing a part for building. It utilizes a spreadsheet format into which
the STL file is loaded and set-up with the appropriate build and recoat
style parameters.
(6) SliceTM Module. This is the second stage of preparing a part for
building. It converts the spreadsheet information from the Part Manager
module to a model of three-dimensional cross sections or layers.
(7)Converge Module. This is the third and last stage of preparing a
part for building. This is the module which creates the final build
files used by the SLA.
 Principle Of SLA
• The SLA process is based fundamentally on following priniciple:

(1) Parts are built from a photo-curable liquid resin that cures
when exposed to a laser beam (basically, undergoing the
photopolymerization process) which scans across the surface of
the resin. The raw material is Photosensitive thermoset polymers
used in this process.

(2) The building is done layer by layer, each layer being scanned by
the optical scanning system and controlled by an elevation
mechanism which lowers at the completion of each layer.
 Photopolymers

► There are many types of liquid photopolymers - solidified by

exposure to electro-magnetic radiation, including wavelengths in the

gamma rays, X-rays, UV and visible range, or electron-beam (EB)

► UV-curab l e photopolymers are resins

► There are a large variety of them and some may contain fillers and

other chemical modifiers to meet specified chemical and mechanical

requirements The process through which photopolymers are cured is

referred to as the photopolymerization process.

 PHOTOPOLYMERIZATION
• Polymerization is the process of linking small molecules (known
as monomers) into chain-like larger molecules.
• When the chain-like polymers are linked further to one another,
a cross-linked polymer is said to be formed.
• Photopolymerization is polymerization initiated by a
photochemical process whereby the starting point is usually the
induction of energy from the radiation source. It terminates for
recombination.
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The free-radical photo polymerization process

Photo initiator molecules, Pi, which are mixed with the monomers, M,
are exposed to a UV source of actinic photons, with energy of hv. The
photo initiators absorb some of the photons and are in an excited state.

Some of these are converted into reactive initiator molecules, P• , after

undergoing several complex chemical energy transformation steps.
These molecules then react with a monomer molecule to form a
polymerization initiating molecule, PM • .

This is the chain initiation step.

Once activated, additional monomer molecules go on to react in the

chain propagation step, forming longer molecules, PMMM• until a chain
inhibition process terminates the polymerization reaction.
 Advantages and Disadvantages
The main advantages of using SLA are:

(1) Round the clock operation. The SLA can be used continuously and
nattended round the clock.

(2) Good user support. The computerized process serves as a good ser
support.

(3) Build volumes. The different SLA machines have build volumes ranging
from small to large to suit the needs of different users.

(4) Good accuracy. The SLA has good accuracy and can thus be used or
many application areas.

(5) Surface finish. The SLA can obtain one of the best surface finishes
amongst RP technologies.
(6) Wide range of materials. There is a wide range of materials, from
general-purpose materials to specialty materials for specific

applications.

The main disadvantages of using SLA are:

(1) Requires support structures. Structures that have overhangs and
undercuts must have supports that are designed and fabricated together

w ith the main structure.

(2) Requires post-processing. Post-processing includes removal af supports

and other unwanted materials, which is tedious, time consuming and can

damage the model.

(3) Requires post-curing. Post-curing may be needed to cure the object

comp letely and ensure the integrity of the structure.
 Applications
The SLA technology provide methods for reducing time to market,

lowering product development costs, gaining greater control of their

design process and improving product design.

(1) Models for conceptualization(an elaborated concept), packaging and

presentation.

(2) Prototypes for design, analysis, verify ,functional testing.

(3) Parts for prototype tooling and low volume production tooling.

(4) Investment casting, sand casting and molding.

(5) Tools for f ixture and tooling design, and production tooling. It is used

as a tooling for Injection moulding.

 Solid Based System - Fused Deposition
Modelling (FDM)
• Fused Deposition Modelling (FDM) was founded in early 1990 by
Strata sys. Inc.
• FDM is a additive manufacturing technology for producing
models, prototypes, and patterns.
• There are several models/Products available in FDM
✓ FDM 3000
✓ FDM Maxum
✓ FDM Titan
 Process ofFDM
• In this patented process , a geornetric model of a conceptual design is
created on a CAD software which uses IGES or STL fonnatted files.
• It can then i1nported into the workstation where it is processed through
the QuickSlice® and SupportWork software.
• Within this software, the CAD fi le is sliced into horizontal layers after
the part is oriented for the optimurn build position, and any necessary
support structures are automatically detected and generated.
• The slice thickness can be set manually to anywhere between 0.172 to
0.356 m.rn (0.005 to 0.014 in) depending on the needs of tbe models.
Suppo1t structure required when the CAD 1nodel having an angle of
below 45 degree.
• The modelling materia l is in spools - very n1uch like a fishing
line.The filament 011 the spools is fed into an extrusion head and heated
to a sen1i-liquid state. Support material is used to support overhanging
sections and undercu tting sections.
 Process OfFDM
• The se1ni-liquid n1aterial is extruded through the head and then
deposited in ultra thin layers frotn the FDM head, one layer at a time.
• Since the air surrounding the bead is n1aintained at a ten1perature
below the tnaterials' melting point, the exiting n1aterial quickly
solidifies.
• Moving on the X- Y plane, the head follows the tool path generated by
QuickSlice® or Ins ight generating the des ired layer.When the layer is
completed, the bead moves on to create the next layer.
• The hori zontal width of the extruded material can vary between 0.250
to 0.965 mn1 depending on 1nodel. Reduce the warpage of processed
parts by printing with raft on, proper bed preparation and using
sticking agent.
• Two modeler materials are dispensed through a dual tip n1echanism in
the FDM n,achine.
• A prin,ary 1nodeler rnaterial is used to produce the model geo1netry
• Secondary n1aterial, or release material, is used to produce the support
structures.
Fused Deposition Modeling {FDM)

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 Principle Of FDM
• The principle of the FDM is based on surface chemistry, thermal
energy, and layer manufacturing technology.
• The material in filament (spool) form is melted in a specially
designed head, which extrudes on the model.
• As it is extruded, it is cooled and thus solidifies to form the
model.
• The model is built layer by layer, like the other RP systems.
• Parameters which affect performance and functionalities of the
system are material column strength, materia l flexural modulus,
materia l viscosity, positioning accuracy, road widths, deposition
speed, volumetric flow rate, t ip diameter, envelope
temperature, and part geometry.
 Advantages of FDM
(1 )Fabrication ofji111ctio11a/ parts : FDM process is able to fabricate
prototypes with materials that are similar to that of the actual 1nolded
product. With ABS, it is able to fabricate fu lly functional parts that
have 85% of the strength of the actual 1nolded part. This is especially
useful in developing products that reqttire quick prototypes for
functional testing.
(2)Mininzal wastage: The FDM process build pa1ts directly by
extruding semi-liquid melt onto the n1odel. Thus only those 1naterial
needed to build the part and its support are needed, and n1aterial
wastages are kept to a n1inimum. There is also little need for cleaning
up the model after it has been built.
(3)Ease of support removal.:With the use of Break Away Support
System (BASS) and Waterworks Soluble Support System, support
structures generated during the FDM building process can be easily
broken off or simply washed away. This makes it very convenient for
users to get to their prototypes very quickly and there is very little or
no post-processing necessary.
 Advantages of FDM
(4)Ease of material change: Build materials, supplied in spool form
(or cartridge form in the case of the Dimension or Prodigy Plus), are
easy to handle and can be changed readily when the materials in the
syste1n are running low. This keeps the operation of the 1nachine
simple and the maintenance relatively easy.

Disadvantages of FDM
• Restricted accuracy
• Slow process
• Unpredictable shrinkage
 APPLICATION OF FDM
• FDM can be used in following general application:
(1) Models for conceptualization and presentation. Models
can be marked, sanded, painted and drilled and thus can be
finished to be almost like the actual product.
(2) Prototypes for design, analysis and fi111ctional testing. The
systetn can produce a fuUy functiona l prototype in ABS. The
resulting ABS parts have 85% of the strength of the actual
molded part. Thus actual testing can be ca1Tied out, especially
with consumer products.
(3) Patterns and 111asters for tooling. Models can be used as
patterns for investment casting, sand casting and molding.
 LASER
SYSTEM

COMPONENT
BEING BUILT -+-----D----1►
LAYER BY LAYER

LIQUID
.....H-- + POLYMER
( RESIN)

BUILD TANK
• Stereolithography process is one of
the Rapid Prototyping processes in
which liquid polymer is used as
material for layer by layer 3-D part
y

building with the help of Laser for

x~ x
y
solidification of liquid resin.
• Working Principle - In the
Stereolithography process, As per
the action of the laser beam, a layer Part / Workpiece - 1--- -
I
of liquid resin gets solidified on the
platform. This solidification of the Liquid resin
liquid layer is used to build the part.
Platform
• Stereo-Lithography Machine consists of the following
components:-
• LASER SOURCE
• CONTAINER
• PLATFORM
• 1) LASER SOURCE:- Laser source is used to supply a laser to
solidify liquid resin to build the part in layers.
• 2) CONTAINER:- Container is filled with the liquid resin, When
the laser falls on the liquid resin, the liquid resin gets solidified.
• 3) PLATFORM:- Platform helps in the part building. Platform can
move in an upward and downward direction. Therefore during
part building, the Platform moves downwards so new layers of
liquid resin get solidified on the old solidified layer.
• When the laser source gets on, the Laser falls on the liquid resin
above the platform.
• Hence due to the laser, the Liquid resin layer above the platform gets
solidified.
• Therefore Platform moves downwards and a new solidified layer of
liquids forms on the old solidified layer. In such a way, the platform
moves downwards, and the Product builds on the platform in layers.
• Advantages:-
• Less material waste
• Part with high precision as well as smooth finish can be
produced.
• Disadvantages:-
• The process requires more time.
• High initial investment.
• Stereolithography is a photopolymer-based 3D printing technology.
• SLS works by shining a UV laser against a scanning mirror. The mirror
directs the laser light in a pattern that traces out the cross-sectional
pattern of a single layer of the part.
• This laser light polymerizes the photosensitive resin wherever it hits
a solid surface – either the build platform or the previous layer.
• After each layer is polymerized, the build platform moves upwards.
The part will thus appear to grow out of the liquid.
• SLA 3D printers can produce larger parts with more consistently
smooth organic surfaces when compared to DLP 3D printers.
 Stereo lithography digital
light processing (SLA DLP)
• Similar to SLA, the stereolithography digital light
processing (SLADLP) process uses a liquid
photopolymer as the fabrication material. Whereas
most SLA processes use a single laser source for curing
the photopolymer liquid, SLA-DLP processes cure
entire cross sections at a time using DLP projectors
Working of DLP
• DLP is a "sister technology" to SLA as the only big difference is the
light source used to cure the resin. SLA printers use lasers combined
with galvanometers to cure resin.
• With a DLP 3D printer, the light source is a specially developed digital
light projector screen. Thanks to this screen, DLP is generally
considered to be faster than SLA, and here's why:
• With SLA, the laser has to individually cure the resin in a "point to
point" technique. On the other hand, a DLP projector screen flashes
an image of a layer all at once! Thus all points of a layer can be cured
simultaneously.
• In this way, the print speed is increased in comparison to SLA since it
takes less time to cure a single layer.
• The principle was first used by Envisiontec in the early 2000s
and has since evolved into technologies such as continuous
layer interface production (CLIP),
• The principle, which cures entire cross sections of
photopolymeric material at a time, has both advantages and
disadvantages in comparison to traditional SLA techniques.
• Firstly, it has the potential to speed up the fabrication
process, as the single DLP light source cures entire cross
sections at a time. The DLP projectors may also generate
gradient light sources, making it possible to cure several
layers with different light intensities.
• However, SLA-DLP relies on a DLP projector as the light
source, which has to be mounted under the resin tank and
takes up considerably more space than a desktop SLA printer.
 Difference between DLP and SLA
• Light Source: SLA uses a UV laser beam while the DLP uses UV light from a projector.
• Light Movement: In DLP, the UV light source remains stationary and it cures the
complete layer of resin at a time. In SLA, the laser beam moves from point to point
tracing the geometry.
• Light Intensity: In DLP 3D printer, the operator can control the intensity of UV light
source and thereby control its effect on the resin. In SLA, the intensity of the laser beam
cannot be adjusted and you have to change the laser light completely for different resin
effect.
• Curing: Since the curing (hardening) of the resin is done from point to point, SLA 3D
printing is more accurate and the quality of the print is also better in comparison to
DLP 3D printing.
• Printing Time: The DLP 3D printer works faster and cuts down the 3D printing time
significantly.
• Cost: The UV light source in DLP is cheaper compares to the lasers used in SLA
• Application: DLP is more suitable to build one-off small and intricate part while SLA is
more suitable for printing several intricate parts in one
Working ofDLP
Build plate

•
Resin vat •

Ught be.1m / matrix •

Projector
• Digital light processing is a photopolymer-based 3D printing technology. It
was invented in 1987 by Texas Instruments.
• DLP projects a UV light onto the build platform to polymerize each part
layer.
• The layer’s cross-section must be masked so only the specified areas get
polymerized.
• This masking is done with a DMD (Digital Micromirror Device) containing
thousands of microscopic swiveling mirrors to direct light.
• They are arranged into a digital pattern for each layer to direct the UV
light to the photopolymer or a heat sink below.
• Alternatively, LED screens can be used as the light source, and the masking
is done by simply turning off the LEDs wherever polymerization is not
required.
• The resolution of a DLP 3D printer depends on the resolution of the
LED or DMD array as well as the distance from the light source to the
polymerization zone.
• DLP parts comprise cubic volumes called voxels – essentially 3-
dimensional pixels. This means any curved edge will look like it was
built from many tiny cubes.
• Since a DLP 3D printer uses a digital projector screen, the
resolution of your print directly corresponds to the
resolution of your projector. In other words, a cheaper
projector will likely mean reduced resolution.
• This is in contrast to SLA, where even cheaper devices are
likely to have decent resolution (i.e. a narrow beam width).
Design considerations of SLA-DLP printing
• SLA-DLP printers are typically capable of fabricating with layer
thicknesses varying from 0.015 mm to 0.15 mm.
• Capable of producing high-resolution parts and producing surfaces of
near-injection-molded quality.
• The process often requires additional support structures, which may
require postprocessing.
• To minimize the amount of support structures needed, parts may be
either tilted to minimize overhangs or specifically designed with
angled overhangs.
• A common rule-of-thumb is to avoid overhangs of less than 30°.
Materials in the SLA-DLP
• Much like the SLA process, SLA-DLP materials are available in a range
of material qualities, from clear, translucent plastics to biocompatible
dental materials.
• Most of the available technologies make use of proprietary materials.
 Attribute SLA DLP

Print resolution 25 - 300 microns without voxel pixelation 25 - 300 microns with voxel pixelation

Can print larger parts Yes No

Wide range of material colors No No

Minimum feature size 100 microns 100 microns

Can produce very smooth organic

Yes No
surfaces

High-speed printing No Yes

Has isotropic material properties Yes Yes

Minimum wall thickness 0.1 to 0.3 mm 0.1 to 0.3 mm

Parts need support structures Yes Yes

Largest print volume 335 x 200 x 300 mm 192 x 108 x 370 mm

 Comparative Advantages
DLP printers can print multiple or large parts faster than
SLA parts have smoother surfaces than those of DLP. This SLA. This is due to the fact that the entire print bed can be
is especially noticeable on curved surfaces. exposed to the light from the projector. Each layer gets
polymerized at once.

DLP light sources are easier to replace and calibrate. This is

SLA printers, in general, can be created with larger build
in contrast to SLA which often requires the machine to be
volumes without sacrificing print resolution.
sent back to the manufacturer for repairs.
Comparative Disadvantages

DLP printers have smaller build volumes. A DLP’s print

SLA 3D printing machines are typically more expensive resolution decreases with distance from the light source. A
than DLP machines. large build volume means more distance, so if it were too
big, the resolution would fall to unacceptable levels.

SLA machines are slower than DLP machines. This is DLP cannot produce truly smooth curved faces. Any
because SLA traces a single laser across the entire cross- complex or organic shape will be built from many smaller
section of the part whereas DLP is able to polymerize an cubic voxels. This gives the part a pixelated look. However,
entire layer at once. this is only noticeable upon close inspection.
SLA vs. DLP: Technology Comparison
• Both SLA and DLP produce parts by polymerizing a liquid
photopolymer resin with a UV light source.
• DLP 3D printers polymerize an entire layer at a time whereas SLA 3D
printers scan the cross-section of each layer using a single focused
laser.
• SLA printers can create smoother parts than DLP printers that tend to
have a pixelated type effect on complex surfaces.
SLA vs. DLP: Material Comparison
• Both SLA and DLP make use of photopolymers that are cured by a UV
light.
• Variants of these photopolymers are available with either short or
long molecular chains.
• Short chains produce stiffer parts while longer-chain polymers make
parts more flexible.
• Photopolymers need to be cleaned in a solvent bath once they’re
finished to remove any uncured resin.
• A post-curing stage using UV light may also be needed to ensure
optimal properties.
SLA vs. DLP: Product Applications Comparison
• SLA and DLP can both produce highly accurate parts with very fine
features.
• They’re often used to create casting patterns for jewelry pieces or
custom dental molds designed to perfectly replicate a patient's dental
structure.
• If parts are to be used in medical or mechanical applications, they
generally need to be post-processed to ensure optimal mechanical
properties.
SLA vs. DLP: Print Volume Comparison
• SLA printers can be built around larger print volumes.
• This is because the resolution of the print is not affected by the distance
from the light source.
• The narrow laser cures only a single point worth of photopolymer at any
given moment.
• DLP printers, on the other hand, need to have a relatively shallow resin
bath as the resolution degrades with distance.
• The light source needs to be placed close to the layer to be polymerized.
• Print volume on DLP printers can be increased with the help of higher
resolution light sources but this makes the printer significantly more
expensive.
SLA vs. DLP: Surface Finish Comparison
• SLA and DLP produce some of the smoothest surface finishes of any
3D printing technology.
• When compared to each other, SLA prints have better surface
finishes, especially on complex curved surfaces.
• An SLA laser will more closely follow a complex curve.
• DLP printers, meanwhile, will create curves by approximating them
with multiple cubic structures.
• This results in a pixelated appearance on complex surfaces.
• The effect is only noticeable upon close inspection and in many cases
is not visible to the casual observer.
SLA vs. DLP: Cost Comparison
• In general, DLP printers are cheaper than SLA printers.
• A typical SLA printer can cost USD - 3,750 whereas an entry-level DLP
printer can cost as little as USD - 500.
What is PolyJet 3D printing?

• PolyJet is a revolutionary multi-material jetting

photopolymer 3D printing technology that brings your ideas
to life with exceptional precision and versatility.
• From prototyping to production, PolyJet offers a wide range
of capabilities, including the creation of complex geometries,
intricate details, full-color combinations, transparencies, and
flexible parts - all in a single model.
•
 How does PolyJet material jetting 3D printing
work?
• PolyJet 3D Printing is an advanced technology that quickly
creates precise parts using photopolymers, UV light, and inkjet
heads.
• It achieves accuracy by layering resins to form digital materials.
• The process starts with a CAD model transformed into a
printable format.
• Drops of photopolymer are jetted onto the build platform, then
cured with UV lamps to bond layers.
• Support materials are dissolved or manually removed for the
finished PolyJet model.
 Why Choose PolyJet?
• Multiple materials, both rigid and flexible, in a single print: Efficient 3D
printing of multiple colors and materials in one model.
• CMF hi-fidelity parts with opacity and ultra transparency
capabilities: Capture attention with visually stunning 3D printed parts.
• Easy digital workflow from concept to production: Seamless transition
from design to production with GrabCAD™ Print.
• Simple print handling workflow: Easy to use and swap out pre-filled
material cartridges and minimal post processing required.
• Complex geometries and intricate details: Unlock limitless design
possibilities by creating smooth, detailed parts.
• Biocompatible materials: Choose from a range of materials for medical
and Dental applications.
Advantages
• Printed parts with Polyjet technology are smooth, polished and
accurately detailed.
• Polished, smooth and detailed prototypes that simulate end use
parts.
• Detailed and precise parts such as realistic teeth and gums, implant
models, and even maxillofacial models
• Create complex shapes, intricate detail, and delicate features.
• Integrate a wide variety of materials and colors into individual models
for unmatched efficiency.
Materials
• Digital Materials
• Digital ABS
• Helios
• VeroClear
• Vero
• Rigur
• TangoPlus
• MED610
• VeroDent
 PolyJet Technical Specifications

Maximum Accuracy 0.1-0.3 mm

Layer Resolution 16 microns, or 0.016mm/0.0006"

Minimum Wall Thickness 1mm

Maximum Part Dimensions (Single
Build) 490 x 390 x 200 mm (19.3 x 15.35 x 7.9 in.)

Shore Hardness Ranges 27A - 95A

matte or glossy, additional finishes available as a
Finishes service
• https://www.bartleby.com/subject/engineering/mechanical-
engineering/concepts/rapid-prototyping

• Refer the link for the topics –

• Fused Deposition Modeling (FDM),
• Solid Ground Curing (SGC),
• Laminated Object Manufacturing (LOM)
2 Marks
• Photopolymers?, Polymerization?
• List out solid and liquid based AM
• Thermoplastic / Thermosetting?
• Advantages and disadvantages of SLA, DLP, Polyjet, FDM, SGC, LOM
• Applications of SLA, DLP, Polyjet, FDM, SGC, LOM
• Print parameters of SLA, DLP, Polyjet, FDM, SGC, LOM
• Applications of SLA, DLP, Polyjet, FDM, SGC, LOM
• Materials used in SLA, DLP, Polyjet, FDM, SGC, LOM
• Definition of SLA, DLP, Polyjet, FDM, SGC, LOM
• What is warping defect in FDM?
 Photopolymers

► There are many types of liquid photopolymers - solidified by

exposure to electro-magnetic radiation, including wavelengths in the

gamma rays, X-rays, UV and visible range, or electron-beam (EB)

► UV-curab l e photopolymers are resins

► There are a large variety of them and some may contain fillers and

other chemical modifiers to meet specified chemical and mechanical

requirements The process through which photopolymers are cured is

referred to as the photopolymerization process.

 PHOTOPOLYMERIZATION
• Polymerization is the process of linking small molecules (known
as monomers) into chain-like larger molecules.
• When the chain-like polymers are linked further to one another,
a cross-linked polymer is said to be formed.
• Photopolymerization is polymerization initiated by a
photochemical process whereby the starting point is usually the
induction of energy from the radiation source. It terminates for
recombination.
• Refer the book uploaded in GCR “Chua Chee Kai, Leong Kah Fai, Lim
Chu-Sing - Rapid Prototyping_ Principles and Applications (2nd
Edition) (2003)”
SELECTIVE LASER SINTERING
• Selective laser sintering (SLS) was
developed and patented by Dr.
Carl Deckard and academic
adviser, Dr. Joe Beaman at the
University of Texas at Austin in
the mid-1980s, under
sponsorship of DARPA
• Selective laser sintering (SLS) is an additive
manufacturing (AM) technique that uses a laser as the
power and heat source to sinter powdered material
(typically nylon or polyamide), aiming the laser
automatically at points in space defined by a 3D
model, binding the material together to create a solid
structure.
• Selective laser sintering (SLS) is a close cousin to direct
metal laser sintering (DMLS), but builds parts made of
plastic rather than metal. SLS uses a computer-
controlled CO2 laser versus an ND: YAG fiber laser for
DMLS, but both “draw” slices of a CAD model in a bed
of material, fusing micron-sized particles of material
one layer at a time.
• An additive manufacturing layer technology, SLS
involves the use of a high power laser (for example, a
carbon dioxide laser) to fuse small particles of plastic,
metal, ceramic, or glass powders into a mass that has
a desired three-dimensional shape.
• The laser selectively fuses powdered material by
scanning cross-sections generated from a 3-D digital
description of the part (for example from a CAD file or
scan data) on the surface of a powder bed. After each
cross-section is scanned, the powder bed is lowered
by one layer thickness, a new layer of material is
applied on top, and the process is repeated until the
part is completed
 2

t
Selective laser sintering process
1 Laser 2 Scanner system 3 Powder delivery system 4 Powder delivery piston 5 Roller 6 Fabrication
piston 7 Fabrication powder bed 8 Object being fabricated (see inset) A Laser scanning direction B Sintered powder
particles (brown state) C Laser beam D Laser sintering E Pre-placed powder bed (green state) F Unsintered material
in previous layers
• STL CAD file format. DTM view software uses the .STL
files. This software do the required orientation and
scaling of parts. This machine has auto nesting
capabilities which will place multiple part optimally in
the build chamber for best processing speed and
results. Once the .STL file is placed and parameters are
set the model is directly built from the sile.
 LASER

◄ ►
R OLLER

Eachl'l)'er
Piston goes
up. T t
Each L'l)'er
Piston moves
Down
 Scanner
System
Laser
Powder

--
Roller . ~
--- r Bed

Powder Fabrication
Delivery
System
r l Piston
 Pm1'der Feed Laser
Roller

Powder Feod
Ca1rlr1dge

Bulkt Envelope
Piston
Powder Fee
Cartridge
 / Lel'I~
C() ~
x-Y scanning m
;· ./ i1to<
Laserb8 am
~ / Sintered pat\

Po-Ndef feeO
piston
'---
pOWOe< !ee<
I supply
au,1d p,s1on
PURPOSE OF SELECTIVE LASER SINTERING
• To avoid a prototyping tool.
• To decrease the time and cost of design to product
cycle.
• It can use wide variety of materials to accommodate
multiple application throughout the manufacturing
process.
 The Selective Laser Sintering process
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• A thin layer of heat-fusible powder is deposited onto the part building chamber.
• The bottom-most cross-sectional slice of the CAD part under fabrication is
selectively “drawn” (or scanned) on the layer of powder by a heat-generating CO2
laser. The interaction of the laser beam with the powder elevates the
temperature to the point of melting, fusing the powder particles to form a solid
mass.
• When the cross-section is completely drawn, an additional layer of powder is
deposited via a roller mechanism on top of the previously scanned layer. This
prepares the next layer for scanning.
• Steps 2 and 3 are repeated, with each layer fusing to the layer below it.
Successive layers of powder are deposited and the process is repeated until the
part is completed.
The SLS® system contains the following
hardware components:
• Build chamber dimensions (381 × 330 × 457 mm)
• Process station (2100 × 1300 × 1900 mm)
• Computer cabinet (600 × 600 × 1828 mm)
• Chiller (500 × 800 × 900 mm)
APPLICATIONS
• As conceptual models - Physical representations of designs used to review
design ideas, form and style.
• Functional models and working prototypes - Parts that can withstand
limited functional testing, or fit and operate within an assembly.
• Polycarbonate patterns. Patterns produced using polycarbonate, then cast
in the metal of choice through the standard investment casting process.
These build faster than wax patterns and are ideally suited for designs with
thin walls and fine features. These patterns are also durable and heat
resistant.
• Metal tools - Direct rapid prototype of tools of molds for small or short
production runs.
Advantages
• Good part stability
• Wide range of processing materials
• No part supports required
• Little post-processing required
• High throughput capabilities
• Self-supporting build envelop
• Parts are completed faster
• Damage is less
• Less wastage of material
• Advanced software support
DISADVANTAGES
• Initial cost of system is high
• High operational and maintenance cost
• Peripheral and facility requirement
• Large physical size of the unit
• Higher power consumption
• Poor surface finish
Materials
• Polyamide.
• Thermoplastic elastomer.
• Polycarbonate.
• Nylon.
• Metal.
• Ceramics.
Examples
• Boeing Uses Prototyping to
Maximize Return on
Investment - Boeing used
the Sinterstation to
prototyped visualization and
technical review models,
reproduce existing parts,
and produced scaled
models for laboratory
testing.

RP part for aerospace and defense industry

(Coutesy 3D Systems)
Examples
• Reebok Uses SLS Process for
Developing Sports Shoes -
Traditional prototyping
methods would have taken
30 to 60 days and the
company decided to use the
SLS system and this took
only seven hours and about
US$250 worth of materials.

Prototypes for Reebok golf shoe soles produced by SLS®

(Courtesy 3D Systems)
Examples
• Reebok Uses SLS Process for
Developing Sports Shoes -
Traditional prototyping
methods would have taken
30 to 60 days and the
company decided to use the
SLS system and this took
only seven hours and about
US$250 worth of materials.

Prototypes for Reebok golf shoe soles produced by SLS®

(Courtesy 3D Systems)
Examples
• Rover Applies SLS Process in Tooling for Injection Molding -

Metal injection molding tools produced by SLS®

(Courtesy 3D Systems)
 LASER ENGINEERED NET SHAPING (LENS)
THE PROCESS
• A laser beam [1] created by a laser
generator is focused through a lens
[2] onto the workpiece. Metal
powder [3], or metal wire, is
introduced at the focus of the laser
beam, where the metal powder and
workpiece melt and thus building on
the surface. An inert gas [4] is
supplied to protect both the laser
and the melt from contamination
during the welding process.
~ MAtU,t!C IUIK,GUIDE
• Laser powder forming, also known by the proprietary name (laser
engineered net shaping) is an additive manufacturing technology
developed for fabricating metal parts directly from a computer-aided
design (CAD) solid model by using a metal powder injected into a
molten pool created by a focused, high-powered laser beam.
• A high power laser is used to melt metal powder supplied
coaxially to the focus of the laser beam through a deposition
head. The laser beam typically travels through the center of
the head and is focused to a small spot by one or more
lenses. The X-Y table is moved in raster fashion to fabricate
each layer of the object. The head is moved up vertically
after each layer is completed.

• Metal powders are delivered and distributed around the

circumference of the head either by gravity, or by using a
pressurized carrier gas. An inert shroud gas is often used to
shield the melt pool from atmospheric oxygen for better
control of properties, and to promote layer to layer adhesion
by providing better surface wetting.
 Process
• A deposition head supplies metal powder to the focus of a high powered
Nd:YAG laser beam to be melted. This laser is typically directed by fiber
optics or precision angled mirrors.
• The laser is focused on a particular spot by a series of lenses, and a motion
system underneath the platform moves horizontally and laterally as the
laser beam traces the cross-section of the part being produced. The
fabrication process takes place in a low-pressure argon chamber for oxygen-
free operation in the melting zone, ensuring that good adhesion is
accomplished.
• When a layer is completed, the deposition head moves up and continues
with the next layer. The process is repeated layer by layer until the part is
completed. The entire process is usually enclosed to isolate the process
from the atmosphere. Generally the prototypes need additional finishing,
but are fully dense products with good grain formation.
 Powder
Delivery
Focused Nozzle
Laser Beam

Deposition
Surface

X·Y Motion
Principle
• A high powered Nd:YAG laser focused onto a metal substrate creates
a molten puddle on the substrate surface. Powder is then injected
into the molten puddle to increase material volume.
• A “printing” motion system moves a platform horizontally and
laterally as the laser beam traces the cross-section of the part being
produced. After formation of a layer of the part, the machine’s
powder delivery nozzle moves upwards prior to building next layer.

neodymium-doped yttrium aluminium garnet

Applications
• The LENS technology can be used in the following areas:
• (1) Build mold and die inserts
• (2) Producing titanium parts in racing industry
• (3) Fabricate titanium components for biological implants
• (4) Produce functionally gradient structures
Medical LENS produced metal part
(Courtesy of Optomec Inc.)
Advantages
• Superior material properties.
• Complex parts.
• Reduced post-processing requirements.
Disadvantages
• Limited materials.
• Large physical unit size.
• High power consumption.
Electron Beam Melting (EBM)
• Electron beam melting (EBM), also known as selective electron beam
melting (SEBM)
• Uses a high-energy electron beam as a thermal energy source to fuse
the powder.
• It is fairly comparable to SLM in its working principle, but it does have
its specifics, with the heat source being a major difference.
Schematic of an EBM apparatus

Filament

Grid Cup - - - - - 1171lfl

Anode - - - - - - ,

Focus coiling
------+
(controls spot size)

Electron Beam - - + - - - - - -

Powder Hopper-----<------

Vacuum Chamber ------

Build Platform --+-----v.

• The electron beam in an EBM process is basically generated
by a so-called electron gun. Under vacuum conditions, the
electron gun extracts electrons from a filament (usually
made of tungsten) with a voltage range of 30-60 kV and
discharges them at approximately half the speed of light
towards a layer of metal powder that has been predeposited
on the build plate.
• The electron beam is directed with the help of two magnetic
fields: one acting as a magnetic lens to narrow down the
beam’s diameter and the other to deflect the beam towards
the desired target points on the powder bed.
• The electron bombardment instantly converts the electrons’ high
kinetic energy into thermal energy, which raises the powder’s
temperature beyond its melting point and enables the selective
fusion of particles in the powder bed.
• This continues until the part is constructed in a layer-by-layer fashion
(similar to SLM). Here, high-vacuum conditions are crucial to
circumvent issues like oxidation, contamination, and atmospheric
interference.
• EBM is capable of processing highly reactive metals and high-melting-point
metals and can provide exotic mechanical properties as a result.
• The most commonly used materials in EBM are titanium and chromium-
cobalt alloys.
• Titanium alloys, for example, are of particular interest due to their
biocompatibility, lightweight, and high mechanical strength.
• That is why it is ideal for applications that include spacecraft and
biomedical implants.
• Turbine blades and engine parts are some of EBM’s most common
applications.
• EBM has proven to have a much higher manufacturing speed than SLM but
tends to have lower accuracy and finish quality.
Process
• The part to be produced is first designed in a 3D CAD program.
The model is then sliced into thin layers, approximately a tenth of
a millimeter thick.
• An equally thin layer of powder is scraped onto a vertically
adjustable surface. The first layer’s geometry is then created
through the layer of powder melting together at those points
directed from the CAD file with a computer-controlled electron
beam.
• Thereafter, the building surface is lowered and the next layer of
powder is placed on top of the previous layer. The procedure is
then repeated so that the object from the CAD model is shaped
layer by layer until a finished metal part is completed.
Principle
• Parts are built up when an electron beam is fired at the
metal powder. The computer controlled electron beam in
vacuum melts the layer of powder precisely as indicated by
the CAD model with the gain of the electrons’ kinetic
energy.
• The building of the part is accomplished layer by layer. A
layer is added once the previous layer has melted. In this
way, the solid details are built up of thin metal slices
melted together.
Applications
• The EBM process is used to manufacture H13 tool
steel injection and compression molding tools,
functional prototypes and components in small
batches.
 Differences between EBM and SLM
Characteristic Electron beam melting Selective laser melting
Thermal source Electron beam Laser
Atmosphere Vacuum fuert gas
Scanning Deflection coils Galvanometers
Energy absorption Conductivity-limited Absorptivity-limited
Powder pre-heating Use electron beam Use infrared heaters
Scan speeds Very fast, magnetically-driven Limited by galvanometer inertia
Energy costs Moderate High
Surface finish Moderate to poor Excellent to moderate
Feature resolution Moderate Excellent
Materials Metals (conductors) Polymers, metals and ceramics
 Selective Laser Selective Laser Electron Beam
Sintering Melting Melting
below the melting above the melting above the melting
Melting Point
point point point
all materials,
Materials all materials all materials especially titanium
alloys
Type of Beam laser beam laser beam electron beam

Energy Saving ++ + +++

Melting Ratio partial fully fully

 EBM SLM
electron beams are made up of a stream of electrons moving laser beams are made up of photons moving at the speed of
near the speed of light, light.
electron beam is passed through a gas at atmospheric
a laser beam can pass through a gas unaffected as long as the
pressure. the electrons interact with the atoms in the gas and
gas is transparent at the laser wavelength.
are deflected
EBM is practiced in a low-partial-pressure vacuum SLM is practiced in an inert gas atmosphere at atmospheric
environment pressure

Electrons have a negative charge and are focused and photons are optically focused and deflected using mirrors
deflected magnetically attached to motors.

magnetic coils have an almost instantaneous response to

laser beam focal spot to move from point A to point B, the
changing input conditions, an electron beam can be scanned
galvanometer motors have to move the mirrors accordingly
slowly or very rapidly
virtually instantaneous motion is not possible and the scan
an electron beam can be moved instantaneously from one
speed is determined by the mass of the mirrors, the
location to another without needing to traverse the area in-
characteristics of the motors, and the distance from the mirrors
between
to the powder bed.
Electron beams, however, heat powder by transfer of kinetic Laser beams heat the powder when photons are absorbed by
energy from incoming electrons into powder particles. powder particles
BF Process SLS SLM EBM
Fusion source Laser Laser Electron beam
Compatible Materials Polymers, metals Metals Metals (limited)
Printing resolution 20-150 μm 20-200 μm 50-150 μm

No need for support structures No need for support structures No need for support structures
High speed High accuracy High speed
Excellent layer adhesion Good functionality No oxidation and no residual stress
Pros
Great for post-printing Doesn’t need a lot of post-processing Preheating limits deformations

Recyclability of unused powder Recyclability of unused powder

(recommended amount: 50% recycled (recommended amount: 50% recycled Minimum material waste
powder) powder)
Poor structural integrity (brittle and High surface roughness and residual
Relatively low resolution
porous material) stress
Prone to shrinkage and warping Anisotropic properties Limited commercial options
Cons
Requires a lot of post-process cleaning Requires a supply of inert gas Highly energy-intensive
Relatively small size of
Produces relatively a lot of waste Accuracy requires a longer process time
manufactured part
Expensive Expensive Highly expensive
• As powder particles absorb electrons they gain an increasingly negative
charge. This has two potentially detrimental effects:
1. if the repulsive force of neighboring negatively charged particles
overcomes the gravitational and frictional forces holding them in place,
there will be a rapid expulsion of powder particles from the powder bed,
creating a powder cloud; and
2. Increasing negative charges in the powder particles will tend to repel the
incoming negatively charged electrons, thus creating a more diffuse
beam.

THERE ARE NO SUCH COMPLIMENTARY PHENOMENA WITH PHOTONS

• EBM the powder bed must be conductive. Thus, EBM can only be used to
process conductive materials (e.g., metals) whereas, lasers can be used
with any material that absorbs energy at the laser wavelength (e.g., metals,
polymers and ceramics).
LASER POWDER BED FUSION aka SLM
• In SLM, a high-powered laser selectively melts metal
powder into a part in a layer-by-layer process. SLM is
distinct from similar powder bed fusion techniques such as
selective laser sintering (SLS) and direct metal laser
sintering (DMLS) in that it fully melts metal, instead of
sintering it (fusing it without reaching a liquid state).
High-Power Laser Lenses cG,
~ }:- :-- - " ' -\ • --------------------------- X-Y Scanning Mirror

Inert Shield Gas •- •--------- -- Powder Roller/Recoater

Chamber
.. ______
,. ---
. ~-
·~,·· t:. ,- • ,J' ':'.

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,~•
\ .....,
,
, . ,
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,.. •----'---- -- Objecl/Workpiece
- -- · #' - -- -
.. ·t~;-\ ·,. •. ·-;-;,~·::~~!•
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.,. ______ _ . ·.'\. '.',~

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~ .... ·-:--~'.'.'.
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ADVANTAGES
• SLM creates fully metal, high-performance parts that are highly accurate
and detailed
• The range of materials in SLM is large, encompassing high-strength and
specialty metals
• SLM can reduce part numbers by printing whole assemblies, and can create
highly complex geometries
• SLM speeds up metal manufacturing techniques, reducing delays in repairs
and increasing the pace of production
• SLM reduces material usage and waste, especially when compared to
traditional manufacturing methods
DISADVANTAGES
• Only single-component metals and specified materials with good flow
characteristics are acceptable in SLM
• SLM is a high-energy process, leading to temperature gradients that can
stress/dislocate parts and compromise their structural integrity
• SLM parts need extensive support structures and SLM requires a source of
inert gas
• SLM parts have a rough surface finish out of print and require a lot of post-
processing to take place
• SLM has a size restriction on parts and is very expensive, limited it to small-
batch production runs
APPLICATIONS
• Aerospace industrial components
• Motor parts
• Dental and medical engineered equipment (implants, prosthetics, etc)
• High-pressure resistant components for mechanical/chemical engineering
• Bespoke parts for automotive applications
• Conformal cooling channels in production tool inserts
WAX PRINTING – Principle, Process, materials used
and applications.
• Similar to investment casting

il-
30 Model of the object of the o Je • yer a
~,., - - d·nwax
Object printe 1

,,. i0
- -
<@
and removing it FilUng the empty space Final object in met
Building a mo Id. around the
w.1x ob1ect
Melting the wax
We obtain an empty
corresponding to
:e ace in the mold
final object
with molten metal
• Lost-wax casting – also called investment casting,
precision casting, is the process by which a duplicate
sculpture is cast from an original sculpture. Intricate
works can be achieved by this method.
• In addition to the lost-wax casting process, it is
possible to actually 3D print wax. The material often
used to print wax is not real natural wax, but it is a
wax-like material, the mechanical properties of this
material are then similar to wax.
wax
model

casted
model
--Y--x
• Wax 3D printing and lost wax casting are used to build
your design when using this material. The wax printing
process is a type of stereolithography that uses a wax-like
resin.
• Support structures are printed along with the model to
make sure your model doesn’t fall apart. These support
structures are automatically generated and manually
removed after the printing process. After support
structures are removed and your model is cleaned, the
model can be prepared for casting.
• The plaster mold is then put in an oven and heated for
several hours to a point where the wax is completely
burned out.
• Then, the molten metal is poured in to fill the cavities left
by the wax. Once the metal has cooled and solidified, the
plaster mold is broken and the metal models are removed
by hand. Finally, your model is filed and sanded to get rid
of the sprues. It will be sanded, polished or sandblasted
for the finish you desire.
Materials Used
• Gold
• Silver
• Bronze
• Brass
• Copper
 BIO ADDITIVE
MANUFACTURING
Bioprinting
Techniques and Risks for
Regenerative Medicine

Maika G. Mitchell
3
Bio-ADDITIVE
MANUFACTURING
 What is 3d printing?
“3D printing or additive
manufacturing is a process of making
three dimensional solid objects from
a digital file. The creation of a 3D
printed object is achieved using
additive processes. In an additive
process an object is created by laying
down successive layers of material
until the entire object is created.
Each of these layers can be seen as a
thinly sliced horizontal cross-section
of the eventual object”.
BIO-PRINTING

3D bio-printing helps constructing living

human tissues and organs

Printing process is made by using printing

layer-by-layer approach to generate desired
part of the body .

3D organs liver, kidney, bones, aortic valve

or even heart.
Why..?
• Each day 79 receive
organ each day while
l2 o ,~

18 will die from a lack IQ),~

IO¼,

of one
• Most needed organs .!
80.DQ1

are kidneys, livers, :

l

lungs, hearts.
'o 6 0 ,~
iE
,
;r
40.DQ1

1 0 .~

200g
1005 1007
1999 1001 lOOJ
1997
l99J 1995
1989 l99J r,., r,.,
How…?
Decreased animal testing

Faster and more precise than traditional methods of building organs

by hand

Significantly less expensive products created

Decreased waiting times for organ donors

Less liable to human error

 How to print an organ
@jj:uji@il:@Ni • First, doctors make CT or MRI
Organs could be built up layer by layer by printing clumps ofcells onto agel that turns solid when scans of the desired organ.
• Next, they load the images into
warmed. Once the eel~ have fused the gel can be removed simp~ by cooling~

a computer and build a

corresponding 3-D blueprint of
the structure using CAD
software.
• Combining this 3-D data with
histological information
collected from years of
microscopic analysis of tissues,
scientists build a slice-by-slice
model of the patient's organ.
Each slice accurately reflects
how the unique cells and the
surrounding cellular matrix fit
together in three-dimensional
space.
 NUS
tfatio11al U'n i·•er"iity
of Smg apo re-
Bioprinting process flow
'
Computer
model

3 important components: Bioink, Biopaper, Bioprinter.

[AJ [BJ [ CJ [OJ

Bioink sp heroids Additional laye rs Bioink spheroids Final living
printed into layer printed to build fuse together and tissue
of biopaper gel object biopaper dissolves

Bioink (cells of sp. organ), Biopaper (collagens, nutrients)

Source: organom.com. _.l·ili:h·:ili@·\·

 Components Needed for bioprinting

Cells
+ Hydrogel
+ Bioprinter
- Bioprinted
tissue or
organ

(Bioink)
(Biopaper)

Pre- processing

3 phases Processing

Post processing
26 December 2023 11
 IBioimaging ~ ~
I Blueprint
I. Pre-processing .._ _ _ _..,.
I
- -_B_io_in_k_1,
--_I )
- - - - -
Biopaper I

------
II. Processing
Biopr;nier

--
I
- - ~
-----
I
Marurogens ,, ) Biomoniroring

I I 13
Ill. Post-processing
Bioreactor
Steps in Bioprintingl

26 December 2023 12
 Creating Bioink
When enough cells
.-
1 Cells
are produced, they
are collected to
Sourced from
make Biolnk.
patient biopsies
or stem cells, and
grown using • Formed into
standard spheroids
methods • loaded into a
and techniques. cartridge to create
the BioInk.

rJ Cultured

Cells are cultured in a

growth medium,
enabling cells to multiply
and grow.
26 December 2023 13
Micro-gel or Hydrogel
Unlike the ink you load into your printer at
home, bio-ink is alive, so it needs food, water and
oxygen to survive. This nurturing environment is
provided by a micro-gel think gelatin enriched with
vitamins, proteins and other life-sustaining
compounds. Researchers either mix cells with the
gel before printing or extrude the cells from one
print head, micro-gel from the other. Either way,
the gel helps the cells stay suspended and
prevents them from settling and clumping.
How do they print an organ.
• After that, it's a matter of hitting File > Print, which
sends the modeling data to the bio-printer.
• The printer outputs the organ one layer at a time,
using bio-ink and gel to create the complex
multicellular tissue and hold it in place.
• Finally, scientists remove the organ from the printer
and place it in an incubator, where the cells in the bio-
ink enjoy some warm, quiet downtime to start living
and working together
[A] [B] [C] [D]
Bioink spheroids Additional layers Bioink spheroids Final living
printed into layer printed to build fuse together and tissue
of biopaper gel object biopaper dissolves
Last step and the challenging one!
The final step of this process -- making printed
organ cells behave like native cells -- has been
challenging. Some scientists recommend that bio-
printing be done with a patient's stem cells.
After being deposited in their required three-
dimensional space, they would then differentiate into
mature cells, with all of the instructions about how to
"behave." Then, of course, there's the issue of getting
blood to all of the cells in a printed organ.
Currently, bio-printing doesn't offer sufficient
resolutions to create tiny, single-cell-thick capillaries. But
scientists have printed larger blood vessels, and as the
technology improves, the next step will be fully
functional replacement organs, complete with the
vascularization necessary to remain alive and healthy.
 Current Progress
Ear: 250 µm cells and collagen from rat tail make
human ear in 15 min. Post-processing 3 months.
To serve children with hearing loss due to
malformed outer ear.

Kidneys: Layer-by-layer building of scaffold and

deposition of kidney cells. Assembly to be
transferred into patient

BloodVessels: Rigid but non-toxic sugar filaments

form core. Cells deposited around filaments.
Subsequent blood flow dissolves sugar.

26 December 2023 17
Skin grafts: laser scan wound to determine depth
and area. One inkjet ejects enzymes and second,
cells. Layer is finally sealed by human skin cells.
Useful in war and disaster zones.

Bones: Print skeleton with ceramic or Titanium

powder, incubation of 1 day in culture of
human stem cells. Repair of complex fractures
in accident survivors.
NUS
N'atior-.al l."'ti-.-ers~•
of ~rgapore SWOT Analysis
Strengths
s • All vital organs can be printed by one w Weaknesses

3D bioprinter. • Quality of the organs printed.

• Easy to build own custom machine. • Production time.
• Easy to make body parts w ith desired • Technolgy is still in prematured state.
size and shape. • Expensive.
• Huge market potential.
• Provides several entrepreneurial

Opportunities Threats
Improving machine possibilit ies
T • Technology background of the user.
• larger models. • Time taken for printing an organ.
• faster printing. • Cost of organ printing.
• multi colour prints. • In wrong hands, may cont ribute to fake
• active development of biocompatible identity, increase in crime and illegal
materials. activities.
• customization of designs based on
customer needs.
Advantages
 The waiting list for transplant can be reduced considerably.

 Offers high precise resolution scan can be obtain and software can
calculate the exact size of the desired replacement.(eg bones)

 Quick process ,10 days to print an average sized liver and lobe. Time will
be reduced considerable as the technology advances.

 Artificial organ personalized using patients own cells

 No DNA rejection
Disadvantages
 It will bring a major ethical and moral debate on its use .

 Implanted organ can be rejected as body cant accept them as functional

tissue.

 The cost of printers are very expensive.

 Possibly more expensive than regular organ transplant

 Cost of using stem cells

 Not successfully created yet

Direct Shell Production
Casting (DSPC)

22
Step 1: CAD design St.ep 2: Soligen software designs
casting mold

casnng moto

Step 3: The mac hine de posits Step 4: Ink-je t print head de posits
thin layer of powder binders to solidify powder

Step 5: The process repeats Steps 3 and 4 unti l all layers of the mold
are formed
Step 6: Loose powde r is Step 7 : Molte n me tal is poured into
removed from the mo ld to create the fi nished
comple ted mold produc t
 ...
......
. ·-
1. powder distribution
- Aluminum powder is distributed and compressed by
a roller

2. Adhesive fusing by prinrhead

- opernres like a printer, but uses colloidal silica

3. Part complete ~ · Panremov«J

5 . Pan cast in shell

Advantages

(1) Patternless casting.

Direct tooling, thus eliminating the need to produce any patterns.
(2) Functional metal parts.
As a result, functional metal parts (or metal tooling, such as dies for
die casting) could be made directly from the CAD data of the part.
(3) Net-shaped integral molds.
No parting lines, core prints or draft angles are required. Integral
gatings and chills can be added to optimize mechanical properties.
.
Disadvantages

1. Limited materials.
The DSPC only focuses on making ceramics molds primarily for metal
casting
2. Rough surface finish: details down to 0.175mm; tolerance +/- 0.05mm

3. Unbound powder can clog in hidden cavities

4. not commercially available yet

5. small work envelope

Applications

The DSPC Technology is used primarily to create casting shells for

production of parts and prototypes. It aims to be a premier “one-stop
shop” for functional cast metal parts produced directly from a CAD file,
and with no need for pre-fabricated tooling to produce the first article.
DSPC has been used in the following areas:

(1) Automotive industry.

(2) Aerospace industry.
(3) Computer manufacture.
(4) Medical prostheses.
Wa1er Cooled Marine Exhaus1Manifold Ford Cobra R • Intake M anifold

Race cars i1.1take manifold • GM Moto.rsports

Parts Pilots Metal Parts for Caterpillar
Caterpillar needed to prototype a complex engine component within a
week .
They sent the design file of the component via a modem to Parts (a
division of Soligen Inc.) on Wednesday evening.
By Friday, Parts had completed two casting shells with the DSPC
systems.
On Monday, the foundry poured the shells with A356 aluminum.
On Tuesday, the parts were heat treated and machining finished on
Wednesday. On the same day, the fully functional parts were shipped to
Caterpillar for installation on the engine, thus completing the order from
Caterpillar.
This is very much faster than any traditional fabrication process could
deliver.
Current materials in Rapid /Additive
Manufacturing
Materials in AM today

- Thermoplastics (FDM, SLS)

- Thermosets (SLA)
- Powder based composites (3DP)
- Metals (EBM, SLS)
- Sealant tapes, paper (LOM)
- Starch and sugar (3DP)

31
Functional/structural parts

FDM (ABS and Nylon)

SLS (thermoplastics, metals)
EBM (high strength alloys, Ti, stainless steel, CoCr)

Non-functional/structural parts
SLA (resins): smoothest surface, good for casting
LOM (paper), 3D Printing (plaster, sand): marketing and concept
prototypes, sand casting molds

As new materials are introduced, more functional components will be

manufactured (perhaps 30-40% by 2020).

Importantly AM is one of the best approaches for complex architected

materials.

32
Challenges in AM materials properties
predictions
• Most AM processes introduce anisotropy in mechanical properties (z
different from x,y)
• Local differences in laser/EB power (e.g., perimeter vs center) introduce
heterogeneity in mechanical properties
• Laser fluctuations might result in embedded defects that are difficult to
identify
• All existing machines are open-loop: temperature sensors have been
introduced in some processes, but the readings are not used to optimize
the processing parameters on the fly.

33
A word of caution
Tech Consultancy Puts 3D Printing at Peak of "Hype Cycle"

Pe.kof Troustiol Pla(u,uoC

Inna~ Ollillutl onntent Slope of Enlig:htenmtnt Proctu~ivity
Expectation•

Plateau wlll ~ reaell.cl In :

o kts~ than 2 years o 2 10 5 years
time

• 5 tc> 10 years l) more than 10years

........
& bef«e pl81eau

34
Bio-CAD 1nodeling and its
applications
in computer-aided tissue
. .
eng1neenng

Hamza Riaz
UW- l 4-ME-BSC-045
 Layout

• Use of CAD in Bio-Medical engineering

• Overview of computer-aided tissue e ngineering
• B io-CAD modeli ng in CATE
• D ifferent structures of unit cells

Dc.1>anmcn1ofMcc.hanicnl Enginccrins. WEC S/16120177:57:4JrM 2

 Use of CAD in Bio-Medical Engineering

Cad is being used in Bio-Medical Engineering as

• ln C linical medicine
• Jn tissue engineering
• In Customized medical imp lant design

Dc.1>anmcn1 ofMcc.hanicnl Enginccrins. WEC S/1612017 7:57:4JrM J

 Overview of CATE

CATE embraces three major applications in tissue engineering

• computer-aided tissue modeling, including 3D anatom ic
visuali zation, 3D reconstruction and CAD-based tissue modeling
• computer-aided tissue scaffold infonnatics and biomimetic
design , including computer-aided tissue classification and
app lication for tissue identification and characterization at
different tissue hierarchical levels

Oepanm,cni ofMcc.hanicnl Enginccrins. WEC S/1612017 7:57:4JrM 4

 Overview of CATE

• Bio-manufacturing for tissue and organ regeneration, including

computer-aided manufacturing of tissue scaffolds, bio-
manufacturing of tissue constructs, bio-blueprint modeling for 3D
cell and organ printing

Dc.1>anmcn1 ofMcc.hanicnl Enginccrins. WEC S/1612017 7:57:4JrM

 Overview of CATE

Comput er Aided Tissue Engineering

C.-011111ut t"r,..Aldt'd SC':tffolll h 1ro1•m r.lh:,-, tu u l IUu-.~l an u.facturln : rm• •rb-,0 1r
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S/1612017 7:57:4, rM 6
 Bio-CAD modeling in CATE

• Reconstruction of data obtained from the noninvasive images of

MR1 and CT scan in medica l reconstructive software MJMICS
and Geomagic.
• Characterization of heterogeneity of tissue stTucture using
homogenized techniques
• ABAQUS is used to determine the mechanical prope11ies of the
tissues

Dc.1,anmcni ofMcc.hanicnl Enginccrins. WEC S/1612017 7:57:4JrM 7

 Bio-CAD modeling in CATE

• Us ing CAD solid modeli ng based Boolean operations unit cells

relating to the internal architecture of candidate's unit cells are
integrated w ith the shape of bone
• CAD model of bone tissues scaffolds is made having the same
internal and external properties to that of actual replaced bone.
• Process planning and tool path is generated based on solid
fi-eeforrn fabrications techniques that wou ld be able to design the
desired tissue structure by using CAM techniques ill

Oep:inmcn1 ofMcc.h:inicnl Enginecrins. WEC S/1612017 7:57:4JrM S

 Bio-CAD 1nodeling in CATE

20MO,f141NIICiOnflndX>t ~
O,~QlbQf'le,tr ~•

lm ngo lovol pfOat•lri9 of'b onu undriratudy

Solld <roo ron11 f.atulcntfon o r

hutcrogenoo u• scaffold
a1r11cture11

S/16120 17 7:57:4JrM 9
 Different structures of unit cells

Dc1>anmcni ofMcc.hanicnl Engineering. WEC 511<"2017 7:57:4J PM 10

 Thanks

Oc:~nmc,u af M1,.-ch:inical Engfoet-ring, WEC 5/1612017 7:57 PM II

 References

• LJ.l..Bio-CAD modeling and its applications m computer-aided

tissue engineering
• ill W. Sun*, B. Starly, J. Nam, A. Darling

Dc.1>anm,cni ofMcc.hanicnl Enginccrins. WEC S/16120 177:57:4JrM 12

ORGAN PRINTING
• SCAFFOLDS are materials that have been engineered to cause desirable
cellular interactions to contribute to the formation of new functional
tissues for medical purposes.
• Cells are often 'seeded' into these structures capable of supporting three-
dimensional tissue formation. Scaffolds mimic the extracellular matrix of
the native tissue, recapitulating the in vivo milieu and allowing cells to
influence their own microenvironments.
• They usually serve at least one of the following purposes: allowing cell
attachment and migration, delivering and retaining cells and biochemical
factors, enabling diffusion of vital cell nutrients and expressed products,
and exerting certain mechanical and biological influences to modify the
behaviour of the cell phase.
Materials
• Material selection is an essential aspect of producing a scaffold.
• The materials utilized can be natural or synthetic and can be
biodegradable or non-biodegradable.
• Additionally, they must be biocompatible, meaning that they don't
cause any adverse effects to cells.
• Silicone, for example, is a synthetic, non-biodegradable material
commonly used as a drug delivery material,
• while gelatin is a biodegradable, natural material commonly used in
cell-culture scaffolds
Total artificial heart developed at ETH Zurich
3D printing techniques
• Sacrificial writing into functional tissue (SWIFT)
• Stereolithographic (SLA) 3D bioprinting
• Drop-based bioprinting (Inkjet)
• Extrusion bioprinting
• Fused deposition modeling
• Selective laser sintering
Printing materials
• Natural Polymers
• Synthetic Polymers - Synthetic polymers are human made through
chemical reactions of monomers
• Natural-synthetic hybrid polymers
• Types of printers and processes
• The types of printers used for organ printing include
• Inkjet printer
• Multi-nozzle
• Hybrid printer
• Electrospinning
• Drop-on-demand
Applications
• Organ Donation
• Physician and surgical training
• Pharmaceutical research
• Organ-on-a-chip
Bio-CAD 1nodeling and its
applications
in computer-aided tissue

Hamza Riaz
UW- l 4-ME-BSC-045
 Layout

• Use of CAD in Bio-Medical engineeri ng

• Overvie\v of computer-aided tissue engineeri ng
• Bio-CAD modeli ng in CATE
• Different structures of unit cells

Oc.panmcni ofMcc.hanicnl Enginccrins. WEC S/1("20 17 7:57:4, rM 2

 Use of CAD in B io-Medical Engi11eering

Cad is be ing used in Bio-Medica l Eng ineering as

• ln C linical ,neclic ine
• ln tissue enginee ring
• In Custornized medica l imp lant design

Oc.p:inmcni ofMcc.hanicnl Enginccrins. WEC S/1(" 20 17 7:57:4, rM J

 Overview of CATE

CATE e1nbraces three major applications in tissue engineering

• co1nputer-aided tissue 1nodeling, includ ing 3D anaton1 ic
visualization, 3D reconstruction and CAD-based tissue 1nodeling
• cOJnputer-aided tissue scaffold informatics and bion1iinetic
design , including con1puter-aided tissue classification and
app lication for tissue identification and characterization at
different tissue hierarchical levels

Dcpanmcni ofMcc.hanicnl Enginccrins. WEC S/16120 17 7:57:4, rM

 Overview of CATE

• B io-manufactu ring for tissue and organ regeneration , including

co1nputer-aided 1nanufacluring of tissue scaffolds, bio-
111anufacturing of tissue constructs, bio-blueprint n1odeling for 3D
cell and organ printing

Oc.p:inmcni ofMcc.hanicnl Enginccrins. WEC S/1("2017 7:57:4, rM

 Overview of CATE

I Computer A ided Tissue Engineering I

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Dc1>anmcni ofMcchanicnl Enginccrins. WEC S/1("20 17 7:57:4, rM 6

 Bio-CAD modeling in CATE

• Reconstruction of data obtained from the noninvasive images of

MRl and CT scan in n1edica l reconstructive software MJMICS
and Geo1nagic.
• Characterization of heterogeneity of tissue structure usmg
ho1nogen ized techniques
• ABAQUS is used to detennine the 1nechanical prope11ies of the
tissues

Dc1>anmcni ofMcc.hanicnl Enginccrins. WEC S/l(J2017 7:57:4, rM 7

 Bio-CAD modeling in CATE

• Us ing CAD solid modeling based Boolean operations unit cells

relating to the internal architecture of candidate's unit cells are
integrated w ith the shape of bone
• CAD 1nodel of bone tissues scaffolds is n1ade having the same
internal and external properties to that of actual replaced bone.
• Process planning and tool path is generated based on solid
rreefonn fabrications techniques that wou ld be able to design the
desired tissue structure by using CAM techniques ill

Ocpanmcni ofMcc.hanicnl Enginccrins. WEC S/l(J20 l7 7:57:4J rM S

 Bio-CAD 1nodeling in CATE

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 Different structures of unit cells

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Thanks

5/ 1612017 7:57 PM II
 References

• ULBio-CAD modeling and its applications in co1nputer-aided

tissue engi.neering
• illW. Sun*, B. Starly, J. Na 111, A. Darling

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