Basics and Advance: Dr. Rahul Kumar, SOE, DSU
Basics and Advance: Dr. Rahul Kumar, SOE, DSU
Artificial intelligence (AI)/machine learning – enables automatic decision-making based on the reams of data that
manufacturing companies collect. AI/machine learning can analyze all this data and make intelligent decisions based on
the inputted information.
Drones and driverless vehicles – can increase productivity by reducing the number of workers needed to do rote tasks,
such as moving vehicles across a facility.
Block-chain – Blockchain's benefits, including immutability, traceability and disintermediation, can provide a fast and
efficient way to record and store data.
Edge computing – edge computing helps manufacturers turn massive amounts of machine-generated data into
actionable data to gain insights to improve decision-making. To accomplish this, it uses resources connected to a
network, such as alarms or temperature sensors, enabling data analytics to happen at the data source.
Predictive analytics – companies can analyze the use huge amounts of data they collect from all their data sources to
anticipate problems and improve forecasting.
Digital twins – companies can use digital twins to model their processes, networks and machines in a virtual
environment, then use them to predict problems before they happen as well as boost efficiency and productivity.
• Traditional manufacturing methods, developed during the age of mass production, focus on economy of scale and
machine utilization. The thinking was that if a machine was idle, it was losing money, so companies kept them
running continuously.
• To achieve customer satisfaction, traditional manufacturing companies keep large inventories on hand so they can
fulfill potential orders.
• This is known as batch-and-queue processing – a mass production approach to operations where the parts are
processed and moved to the next process, whether they're needed or not, and wait in a line (queue).
• Smart manufacturing, on the other hand, is a collaborative, fully-integrated manufacturing system that responds
in real-time to meet changing the conditions and demands in the factory, in the supply network, and in the needs
of the customers.
• The goal of smart manufacturing is to optimize the manufacturing process using a technology-driven approach
that utilizes Internet-connected machinery to monitor the production process.
• Smart manufacturing enables organizations to identify opportunities for automating operations and use data
analytics to improve manufacturing performance.
Purposes solved
• Dissection and analysis
• Experience and knowledge for an
individual’s personal database
• Competitive benchmarking
INTRODUCTION:
WHAT IS IT:
NAMING:
Rapid Prototyping: This term was used in the beginning of the professional use of the
technology because the main application was the manufacturing of prototypes, mock ups and
sample parts.
Introduction to AM
Stereolithography (SL)
• It is widely recognized as the first 3D printing process. SL is a laser-based process that works with photopolymer resins, that react
with the laser and cure to form a solid in a very precise way to produce very accurate parts.
• It is a complex process in which the photopolymer resin is held in a vat with a movable platform inside. A laser beam is directed in the
X-Y axes across the surface of the resin according to the 3D data supplied to the machine (the .stl file), whereby the resin hardens
precisely where the laser hits the surface.
• Once the layer is completed, the platform within the vat drops down by a fraction (in the Z axis) and the subsequent layer is traced out
by the laser. This continues until the entire object is completed and the platform can be raised out of the vat for removal.
• Because of the nature of the SL process, it requires support structures for some parts, specifically those with overhangs or undercuts.
These structures need to be manually removed. In terms of other post processing steps, many objects 3D printed using SL need to be
cleaned and cured. Curing involves subjecting the part to intense light in an oven-like machine to fully harden the resin.
Stereolithography is generally accepted as being one of the most accurate 3D printing processes with excellent surface finish.
• However limiting factors include the post-processing steps required and the stability of the materials over time, which can become
more brittle.
Additive Manufacturing
• DLP is a similar process to Stereolithography in that it is a 3D printing process that works with
photopolymers. The major difference is the light source. DLP uses a more conventional light source, such as an
arc lamp, with a liquid crystal display panel or a deformable mirror device (DMD), which is applied to the
entire surface of the vat of photopolymer resin in a single pass, generally making it faster than SL.
• Also like SL, DLP produces highly accurate parts with excellent resolution, but its similarities also include
the same requirements for support structures and post-curing. However, one advantage of DLP over SL is that
only a shallow vat of resin is required to facilitate the process, which generally results in less waste and lower
running costs.
Additive Manufacturing
• However, on the downside, because of the high temperatures required for laser sintering, cooling times
can be considerable.
• Furthermore, porosity has been an historical issue with this process, and while there have been significant
improvements towards fully dense parts, some applications still necessitate infiltration with another
material to improve mechanical characteristics.
• Laser sintering can process plastic and metal materials, although metal sintering does require a much
higher powered laser and higher in-process temperatures.
• Parts produced with this process are much stronger than with SL or DLP, although generally the surface
finish and accuracy is not as good.
Additive Manufacturing
• Stratasys has developed a range of proprietary industrial grade materials for its FDM process that are suitable for
some production applications. At the entry-level end of the market, materials are more limited, but the range is
growing. The most common materials for entry-level FFF 3D printers are ABS and PLA.
• The FDM/FFF processes require support structures for any applications with overhanging geometries. For FDM, this
entails a second, water-soluble material, which allows support structures to be relatively easily washed away, once the
print is complete.
• Alternatively, breakaway support materials are also possible, which can be removed by manually snapping them off
the part.
• Support structures, or lack thereof, have generally been a limitation of the entry level FFF 3D printers. However, as
the systems have evolved and improved to incorporate dual extrusion heads, it has become less of an issue.
• In terms of models produced, the FDM process from Stratasys is an accurate and reliable process that is relatively
office/studio- friendly, although extensive post-processing can be required. At the entry-level, as would be expected,
the FFF process produces much less accurate models, but things are constantly improving.
• The process can be slow for some part geometries and layer-to- layer adhesion can be a problem, resulting in parts
that are not watertight. Again, post-processing using Acetone can resolve these issues.
Additive Manufacturing
Short introduction to the technology
Additive Manufacturing
Binder Jetting
AM Materials
• However, there are now way too many proprietary materials from the many different 3D printer
vendors to cover them all here.
• Instead, we will look at the most popular types of material in a more generic way. And also a couple
of materials that stand out.
AM Materials
• Nylon, or Polyamide, is commonly used in powder form with the sintering process or in filament form with the FDM
process. It is a strong, flexible and durable plastic material that has proved reliable for 3D printing. It is naturally white
in colour but it can be coloured — pre- or post printing. This material can also be combined (in powder format) with
powdered aluminium to produce another common 3D printing material for sintering Alumide.
• ABS is another common plastic used for 3D printing, and is widely used on the entry-level FDM 3D printers in
filament form. It is a particularly strong plastic and comes in a wide range of colours. ABS can be bought in filament
form from a number of non- proprietary sources, which is another reason why it is so popular.
• PLA is a bio-degradable plastic material that has gained traction with 3D printing for this very reason. It can be
utilized in resin format for DLP/SL processes as well as in filament form for the FDM process. It is offered in a variety
of colours, including transparent, which has proven to be a useful option for some applications of 3D printing.
However it is not as durable oars flexible as ABS.
Additive Manufacturing
Short introduction to the technology
Additive Manufacturing
AM Materials
• Lay-Wood is a specially developed 3D printing material for entry- level extrusion 3D printers. It comes in
filament form and is a wood/polymer composite (also referred to as WPC).
• A growing number of metals and metal composites are used for industrial grade 3D printing. Two of the
most common are aluminium and cobalt derivatives.
• One of the strongest and therefore most commonly used metals for 3D printing is Stainless Steel in powder
form for the sintering/ melting/EBM processes. It is naturally silver, but can be plated with other materials
to give a gold or bronze effect.
• In the last couple of years Gold and Silver have been added to the range of metal materials that can be 3D
printed directly, with obvious applications across the jewellery sector. These are both very strong materials
and are processed in powder form.
• Titanium is one of the strongest possible metal materials and has been used for 3D printing industrial
applications for some time.
• Supplied in powder form, it can be used for the sintering/melting/ EBM processes.
Additive Manufacturing
Short introduction to the technology
Additive Manufacturing
AM Materials
Ceramics
Ceramics are a relatively new group of materials that can be used for 3D printing with various levels of success. The
particular thing to note with these materials is that, post printing, the ceramic parts need to undergo the same processes
as any ceramic part made using traditional methods of production - namely firing and glazing.
Paper
Standard A4 copier paper is a 3D printing material employed by the proprietary SDL process supplied by Mcor
Technologies. The company operates a notably different business model to other 3D printing vendors, whereby the
capital outlay for the machine is in the mid-range, but the emphasis is very much on an easily obtainable, cost-effective
material supply, that can be bought locally. 3D printed models made with paper are safe, environmentally friendly,
easily recyclable and require no post-processing.
Bio Materials
There is a huge amount of research being conducted into the potential of 3D printing bio materials for a host of medical
(and other) applications. Living tissue is being investigated at a number of leading institutions with a view to
developing applications that include printing human organs for transplant, as well as external tissues for replacement
body parts. Other research in this area is focused on developing food stuffs - meat being the prime example.
Additive Manufacturing
Short introduction to the technology
Additive Manufacturing
AM Materials
Food
Experiments with extruders for 3D printing food substances has increased dramatically over the last couple of
years. Chocolate is the most common (and desirable). There are also printers that work with sugar and some
experiments with pasta and meat. Looking to the future, research is being undertaken, to utilize 3D printing
technology to produce finely balanced whole meals.
Other
And finally, one company that does have a unique (proprietary) material offering is Stratasys, with its digital
materials for the Objet Connex 3D printing platform. This offering means that standard Objet 3D printing
materials can be combined during the printing process — in various and specified concentrations to form new
materials with the required properties. Up to 140 different Digital Materials can be realized from combining the
existing primary materials in different ways.
Additive Manufacturing
Short introduction to the technology
Additive Manufacturing
Advantages:
Advantages:
Tool-less
• For industrial manufacturing, one of the most cost-, time- and labor-intensive stages of the product development process is the
production of the tools. For low to medium volume applications, industrial 3D printing — or additive manufacturing — can eliminate
the need for tool production and, therefore, the costs, lead times and labor associated with it.
• This is an extremely attractive proposition, that an increasing number or manufacturers are taking advantage of. Furthermore, because
of the complexity advantages stated above, products and components can be designed specifically to avoid assembly requirements
with intricate geometry and complex features further eliminating the labor and costs associated with assembly processes.
Sustainable / Environmentally Friendly
• 3D printing is also emerging as an energy-efficient technology that can provide environmental efficiencies in terms of both the
manufacturing process itself, utilising up to 90% of standard materials, and, therefore, creating less waste, but also throughout an
additively manufactured product’s operating life, by way of lighter and stronger design that imposes a reduced carbon footprint
compared with traditionally manufactured products.
No storage cost
• Since 3D printers can “print” products as and when needed, and does not cost more than mass manufacturing, no expense on storage
of goods is required.
Increased employment opportunities
• Widespread use of 3D printing technology will increase the demand for designers and technicians to operate 3D printers and create
blueprints for products.
Additive Manufacturing
Short introduction
Additive to the technology
Manufacturing
Disadvantages:
Questionable Accuracy
3D printing is primarily a prototyping technology, meaning that parts created via the technology are mainly test parts. As with any viable test
part, the dimensions have to be precise in order for engineers to get an accurate read on whether or not a part is feasible. While 3D printers
have made advances in accuracy in recent years, many of the plastic materials still come with an accuracy disclaimer. For instance, many
materials print to either +/- 0.1 mm in accuracy, meaning there is room for error.
Considerable effort required for application design and for setting process parameters
Complex set of around 180 material, process and other parameters and specific design required to fully profit from the technology
Material cost:
Today, the cost of most materials for additive systems ( Powder ) is slightly greater than that of those used for traditional manufacturing .
Additive Manufacturing
Short introduction to the technology
Additive Manufacturing
Disadvantages:
Material properties:
A limited choice of materials is available. Actually, materials and there properties (e.g., tensile property, tensile strength, yield strength,
and fatigue) have not been fully characterized. Also, in terms of surface quality, even the best RM processes need perhaps secondary
machining and polishing to reach acceptable tolerance and surface finish.
Limitations of size
3D printing technology is currently limited by size constraints. Very large objects are still not feasible when built using 3D printers.
Cost of printers
The cost of buying a 3D printer still does not make its purchase by the average householder feasible. Also, different 3D printers are
required in order to print different types of objects. Also, printers that can manufacture in colour are costlier than those that print
monochrome objects.
The AM value chain consists of five steps – AM system providers are active in most areas of the value chain
Application
Material System Software Production
design
Mainly: Creation of >Usually stand- >Differentiation > Support for end >Different production
metal powder alone powder bed between process customers scenarios:
> Powder with high fusion systems control and > Can be complex - Large OEM
purity and a very > System providers enhancement and demanding - Contract
narrow distribution with low levels of software > Done by system manufacturer/service
of the granular size vertical integration, > Process control providers, software provider
(usually 30µm) standard from system prov. developers and/or - Specialized part
> Hard to get from components > Add-on software service providers manufacturer
large providers due usually made by such as automatic > Not every service > Production is normally
to small orders contract support generation, provider is able to not done
>Usually sold by manufacturers design optimization design applications by AM System providers
AM system > Providers By specialized
providers integrate companies
components system
& software
Players: Players: Players: Players: Players:
> Höganäs > EOS > Materialise > 3T PRD > 3T PRD
> TLS Technik > SLM Solutions > netfabb > Concept Laser > Janke Engin.
> San > Concept Laser > With > EOS > Layer Wise
> etc. > etc. > etc. > etc. > etc.
Additive Manufacturing
Short introduction
3D Printing to the technology
History of 3D Printing:
2000-
1980-2000 • The earliest 3D printing technologies first became visible
in the late 1980’s, at which time they were called Rapid
Prototyping (RP) technologies. This is because the
processes were originally conceived as a fast and more
cost-effective method for creating prototypes for product
development within industry.