Additive Manufacturing State of Art

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Materials Today: Proceedings 21 (2020) 628–633

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Materials Today: Proceedings


journal homepage: www.elsevier.com/locate/matpr

Additive manufacturing – State of art


K. Rajaguru a,⇑, T. Karthikeyan b, V. Vijayan a
a
K. Ramakrishnan College of Technology, Trichy 621112, India
b
M.I.E.T. Engineering College, Trichy 620007, India

a r t i c l e i n f o a b s t r a c t

Article history: The emerging trend of manufacturing is keenly focused on increasing the productivity. Many alternatives
Received 4 June 2019 to enhance the productivity of a manufacturing industry involves reformation of production cycle,
Accepted 30 June 2019 increasing the life of cutting tool, reducing the design complexity, etc. However, the increasing nature
Available online 3 August 2019
of size reduction and complexion in design seeks alternate method of manufacturing. The additive man-
ufacturing is an emerging methodology used for meeting the needs of growing demand. It is a process of
Keywords: manufacturing parts by depositing materials which is contrary to that of conventional. The criticality
Additive manufacturing
involved in making full use of this technology are addressed, along with capabilities of meeting extended
Rapid manufacturing
Materials and techniques
product requirements. It also helps in accommodating highly complex design, reduced material waste,
Design for product restoring damaged parts of higher demands, etc. This work presents a complete investigational survey
Pre-processing in additive manufacturing on various additive manufacturing techniques, integration of digital pre-processing procedures, and
product-based process designing. The process of creating models with reduced development and manu-
facturing time is discussed in an absolute manner. Several application-based materials are described in
details along with few properties at the end of rapid manufacturing.
Ó 2019 Elsevier Ltd. All rights reserved.
Peer-review under responsibility of the scientific committee of the International Conference on Recent
Trends in Nanomaterials for Energy, Environmental and Engineering Applications.

1. Introduction 2. Prototyping

Recent trends in the improvement of manufacturing techniques Prototyping is one of the most important product development
has been tremendously increasing with the increase of automation techniques [35]. Prototyping is the process of creating mathemat-
of the processes. Still many manufacturing processes were made ical models, pencil sketches, functional physical models and foam
manually due to the complexity of the process. The source of mate- models into a real physical model. This process of creating scaled
rials and time are the main squeezing parameters in the market objects can be easily checked for faults and flaws in the manufac-
which decides the production process. turing process. Functional component can be checked for errors in
AM techniques can change the face of the manufacturing indus- connections and over loading of the functioning components.
try. This technology is driven through computer programming and Many numbers of changes can be made in the designs and the vari-
software’s. Ease of computing and the manipulation of the data is ations can be checked by creating many prototypes. Iterative pro-
the major positivity for the development of AM. More over the cesses are made simpler by the prototyping process. Prototypes
increase in the researches of AM is made due to the need of proto- can change the flaws created in the manufacturing process during
typing in the product development phase. AM directly involves in the designing [36].
the prototyping process reducing the time and wastage of materi- Rapid Prototyping (RP) usually accelerates the design and pro-
als used on the process. duction process. It can create a defect free product manufactur-
ing. Rough versions can be made easily for the improvement of
the products by introducing the product into a brainstorming
session [1].

⇑ Corresponding author.
E-mail address: roseguruvin@gmail.com (K. Rajaguru).

https://doi.org/10.1016/j.matpr.2019.06.728
2214-7853/Ó 2019 Elsevier Ltd. All rights reserved.
Peer-review under responsibility of the scientific committee of the International Conference on Recent Trends in Nanomaterials for Energy, Environmental and Engineering
Applications.
K. Rajaguru et al. / Materials Today: Proceedings 21 (2020) 628–633 629

3. Materials used in Prototyping: The production of the objects are done after the virtual analysis
of the object in some analysing software’s like ANSYS, COMSOL,
The materials mostly used for development are metal alloys, ABAQUS etc [33]. Models are also created using reverse engineer-
ceramics, polymer composites, concrete [2,28] and Bio compatible. ing process. Scanning machines are available for creating a virtual
Polyether ether ketone (PEEK) can be used for facial implants by prototype model by a simple scan process. The machine uses UV
creating three dimensional implants for complex bone structures light as the source of scanning which is emitted from the source
[3]. Ti-24Nb-4Zr-8Sn are created for Acetebular cup as the material and received back after hitting the target object to be scanned.
has a higher relative density and required mechanical properties The higher resolution of scanning machines resolution of more
[4,34]. Ti-6AI-4V is used for creating rat implants as the porosity than 100 mm are available to scan the objects which uses white
plays an important role for the tissues to grow and bond together or blue light as the source of scanning [40]. These scanners play
to the bones [5]. [39] Ti-6Al-4V is used as a pig skull as Scaffolds a major role in the Reverse engineering process for creating and
were more adaptable for bone ingrowth [6]. Mostly the materials customizing for various application. Prosthetic parts are created
printed in 3d printing are hygroscopic. ABS, BVOH, HIPS and nylon from scanning the bone parts or the outer structure of the human
are highly vulnerable to moisture. Polyaryletherketone (PAEK) and body for creation of the exact replication of the part [3,35].
Polyether ether ketone (PEEK) have been available in the industry
for some time now which offers lower-temperature process win- 4.2. Understanding the functional parts
dow (355–375 °C), compared to both PAEK and PEEK’s processing
range of 350–430 °C [33]. The functional parts are the complex structures created by the
Siemen’s created a pre-mixer for dry low emission burner designers which are taken great care for the production process.
chamber or flame holder using printable nickel as the core for The system of the combined parts are more specifically designed
the super alloys. This is a complex combustion aero derivative with clearance spacing between the parts with higher precision.
component gas turbine. In a report titled ‘‘3D Printed Stem-Cell These parts can be created in AM process as a single parts or as
Derived Neural Progenitors Generate Spinal Cord Scaffolds” a bio assembled components. The parts are to be post processed in some
polymer has been created using silicone and stem cells which is process like SLA for hardening of the material. The movable parts
being created in 3D printing which is used as a small insert in created as an assembly will be designed with a clearance value
between the spinal cord [4]. Techshot and 3D bioprinter develop- for the AM process.
ers, nScrypt, demonstrated that the printing can be done in zero
gravity that’s in space applications. Terminologies used in this arti- 4.3. Converting into .STl
cle is from ASTM standards [29]. Nano materials reinforced mate-
rials are also used for creating parts with higher strength and The models created are converted in to Standard Triangle Lan-
surface finish [44] (see Fig. 1). guage (STL) or Standard Tessellation Language for the slicing pro-
cess. STL file mainly describe the surface geometry of the given
4. Process of AM design file removing all the textures, colors and other CAD attri-
butes [43]. This format also specifies both ASCII and binary code
4.1. Creation of the virtual model representations [22]. The SLT file converts the data of the design
file into a triangulated surface using three dimensional Cartesian
A Virtual model can be created by many modelling software’s co- ordinates. It follows right-hand rule ordering the unit normal
which are existing. The designs are created using the data provided and vertices of the triangles [23].
by the design engineers or the data obtained from the existing
designs [42]. The virtual model is also known as CAD models are 4.4. Slicing and creating supports
widely created in software’s like Autocad, Creo, Solidwork’s, Catia,
Unigraphics ets has the exact values of the original object in real Contour data is being created form the STL files. The slicing pro-
time [45,46] (see Table 1). cess is done horizontally according to the required layer thickness.

Fig. 1. Classification of Additive Manufacturing.


630 K. Rajaguru et al. / Materials Today: Proceedings 21 (2020) 628–633

Table 1
Pure metals components produced by various AM processes.

Metal Powder characteristics Process Laser type Bonding mechanism Mechanical properties Ref.
Ti The Spherical shaped particle LS Pulsed Nd :YAG In between narrow surface Good value of 72% in theoretical density was [16]
with Gaussian distribution laser layers limited melting is achieved with 250–340 HV micro hardness and
having 8 mm average (30 mm applied to avoid phase 260 MPa yield strength.
max.) is used. changes.
Average grains of 45 mm sizes LM Pulsed Nd : YAG Contradictory to the Superior strength of 300 MPa & 100 MPa in Tensile [17,18]
were used. laser former, complete melting & torsional fatigue were obtained. Post glass nitring
of powders took place. process improved the m-hardness to a range of 600–
1000 HV.
Particles with size ranging LMD Nd:YAG laser, Fractional melting of Proof strength in par with human cortical bones of [19]
between 50 and 150 mm of 500 W particles between layers 21–463 MPa was produced, with elasticity modulus
Commercially pure powders for providing desired of 2–45 GPa and 35–42% of porosity (By vol.).
were employed. porous structure.
Ta Particle sizing over the span of LMD Nd:YAG laser, Fractional melting of Superior proof strength of 100–746 MPa with [47]
45–75 mm (99.5% purity) 500 W particles between layers Porosity of 27–55 vol% and 1.5–20GPa Young’s
for providing desired modulus.
porous structure.
Cu Commercially available grade LM Q switched Complete melting of Three dimensional structures with comparatively [20]
particles krypton flash lamp powder. fair strength was obtained with Cu powder.
pumped Nd:YAG
laser, 90 W
Au 24 mm average Particle sized 24 LM Continuous wave Complete melting of Minimum internal porosity 12.5%; maximum micro [21]
carat gold with 10.3 g/cm3 tap ytterbium fiber powder hardness 29 HV
density was experimented. laser, 50 W

*AM, additive manufacturing; LS, laser sintering; LM, laser melting; LMD, laser metal deposition.

Slicing is done uniformly throughout the object. Slicing can also be


done for variable thickness ie the thickness between the slices var-
ies according to the geometry and the capability of the machine
[7]. Higher the layer thickness, lower the surface finishing. Fig. 2
represents the different between the slicing thicknesses of a single
part [37]
Widely in AM industries de facto industry standards are being
used as it has the ability to simplify and triangulate almost any
complex surfaces [8]. The major disadvantage of this slicing is
the software capability. Not all the 3DCAD software’s can do the
process of slicing only a specific software’s [7,9]. CURA is the most
used base slicing software for direct slicing process Meshmixer,
Blender are some of the other software’s. Supports are to be cre- Fig. 3. Left figure represents water soluble support material and right side with
ated in the parts with over hanging structures for a better creation. same material support material.
Water soluble PLA materials are created for easy removal of the
supports. In the Fig. 3 Left object is supported with water soluble some machines only the platform moves in the z direction. These
material and the right one is provided with the same material movements are controlled by the g-code is provided specifically
support. by the individual software’s for the machine [10].

4.5. Export to .gx code file


5. AM techniques

The slicing software creates the G-code for the 3D printing pro-
5.1. Selective laser sintering
cess. The G-code is symmetrical of the CNC machine coding pro-
cess. The coding created provides the movement to the extruder
Selective laser Sintering (SLS) is a technology that uses laser as
head and the platform direction. In some machines the platform
the source for sintering the powder into a single part in a layer by
is fixed and the extruder moves in the x, y and z direction but in
layer process [30]. Sintering/melting (SLS/SLM) are the same pro-
cess. Fig. 4 represents the layout of SLS using CO2 laser. The process
is done in a confined area as the laser is the source of the binding
the light rays are not allowed into the chamber when printing [38].
The powder is filled in the vat for layer spreading. The process
begins with the layer sintering of the powder spread over the plat-
form initially. Then the platform moves in the z axis and the pow-
der is spread over the next layer for further sintering. The process
continues till the object is completed. The metal powders are used
in this process to create a part directly which can also be used as an
end product [22,31].
Electron Beam Melting (EBM) has a vacuum chamber and a
heated platform for the melting process layer by layer using elec-
tron beam source as energy similar to electron beam welding
Fig. 2. Slicing of an object using different thickness. (Fig. 5).
K. Rajaguru et al. / Materials Today: Proceedings 21 (2020) 628–633 631

cyanoacrylate or epoxy resin for improved hardness in the surface


and higher strength.
Fig. 7 Direct laser metal forming/sintering (DLMF/DLMS) higher
precision parts can be made in a single print using this process. The
working of DLFM is similar to SLS process [12,13].

5.2. Stereolithography (SLA)

A stereo lithography apparatus builds the layers on resin layers


using Scanning lasers or light projectors [32]. Resins used here are
photopolymers cured by light [27]. Each layer is created by the
tracing of the light or laser over the resin surface on the build plat-
form (Fig. 8). Once the layer is build platform moves immersing
into the resin and a coater is used to level the layer of resin to
the layer thickness in the input parameters [11]. The major restric-
tion in this process is the size of the objects created. The process is
done in a light proof room as the resin is photo sensitive. When the
bed area is increased the deposition of the resin layer may create
an uneven layer. This process is mainly used for dental applications
and smaller parts like gold ornament molding etc. [26] Casting
resin can be used like for creating dental components. Direct end
user components for dental purpose can also be created using
SLS technique.
Fig. 4. Selective laser Sintering (SLS) layout.

Fig. 5. Nozzle of Electron Beam Melting (EBM).

Powder Binder Printers (PBP) has a jet nozzle modified to print


with the specific liquid to accurately infiltrate through the powder
layer to harden the surface. This process can be created with color Fig. 7. Direct laser metal forming/sintering (DLMF/DLMS).
textures for real tie study of the prototypes created. Fig. 6 Scanning
of a human head can be done with color textures and printed
using this process [48]. Post processing is done by infiltrating

Fig. 6. Powder Binder Printers (PBP) machine on the left and a human portrait in 3D
with color binders. Fig. 8. Stereolithography.
632 K. Rajaguru et al. / Materials Today: Proceedings 21 (2020) 628–633

Fig. 9. Fusion deposition Modelling (FDM).

5.3. Inkjet printing and contour crafting (IJP) complex removal of support materials are done with some diffi-
culty. Ultimaker has created a water-soluble support material
The liquid resin is made to stream through a micro-nozzles to which leaves no traces in the supported parts creating a clear part.
create a thin layer over the platform. The movement of the extru- Dynamic structures can be easily created using these type of sup-
der head is in the contour created by the part shape in the slicing port materials. Accuracy of the part created depends on the travel
process. The curing of the resin is done by air for some resins but of the extruder, temperature, speed and the flow rate of the mate-
mostly the resin printed objects are kept in UV curing for higher rial through the nozzle. This FDM is widely used in creation of
hardening and stiffness. anatomical models helping in dentistry and for surgical practice
sessions [15].
Fig. 10 represents a raft creation for materials with warping
5.4. Fused deposition modelling (FDM) property. This structured base laver is created to avoid warping
of the correct object or moving of the object from the platform
The Fusion deposition Modelling (FDM) or Fused Filament due to bad adhesion.
Fabrication (FFF) is old method of creating the parts in the AM pro-
cess (Fig. 9). Here the source material is the filaments of different 6. Conclusion
thermosetting plastics [24]. Some materials are bio degradable
polymers (PLA) used as a key element in scaffold structures The advancements of AM technology both in metals and poly-
[14,41]. The filament is melted into a semisolid state and made mers side creates a vase area of research criteria making the basic
to flow on the platform through an extruder nozzle of different complex structures easy to produce. The major drawback of these
sizes [25]. Mostly the extruder moves in x, y direction reading processes is the batch production of large size components. Time
the g-code generated by the slicing software. Some machines the consumption of creation of complex structures and flexible mate-
extruder moves in the z direction and in some other the platform rials are high. The basic steps of AM process have been discussed
does. above.
Some materials need platform heated for better adhesion and to
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