Course Content

 Module 1:
Introduction to Additive Manufacturing (AM): General
overview Introduction, The Generic AM Process, The
Benefits of AM, Distinction between AM and CNC
machining, need for the time compression in product
development, history of RP systems, survey of applications,
classification of AM
 SLE: Reverse Engineering Technology. 08Hrs
 ADDITIVE
MANUFACTURING
 General overview
Introduction
 One of the important steps prior to the production of a
functional product is building of a physical prototype.
 Prototype is a working model created in order to test various
aspects of a design, illustrate ideas or features and gather
early user feed-back.
 Traditional prototyping is typically done in a machine shop
where most of parts are machined on lathes and milling
machines. This is a subtractive process, beginning with a
solid piece of stock and the machinist carefully removes the
material until the desired geometry is achieved.
 General overview
Introduction
 For complex part geometries, this is an exhaustive, time
consuming, and expensive process.
 A host of new shaping techniques, usually put under the
title Rapid Prototyping, are being developed as an
alternative to subtractive processes. These methods are
unique in that they add and bond materials in layers to
form objects. These systems are also known by the names
additive fabrication, three dimensional printing, solid
freeform fabrication (SFF), layered manufacturing etc.
General overview
Introduction
 These additive technologies offer significant advantages in many
applications compared to classical subtractive fabrication methods like
formation of an object with any geometric complexity or intricacy
without the need for elaborate machine setup or final assembly in very
short time.

 This has resulted in their wide use by engineers as a way to reduce time
to market in manufacturing, to better understand and communicate
product designs, and to make rapid tooling to manufacture those
products. Surgeons, architects, artists and individuals from many other
disciplines also routinely use this technology.
 General overview Introduction
• Rapid Prototyping (RP) techniques are methods that allow designers to
produce physical prototypes quickly.
• It consists of various manufacturing processes by which a solid physical
model of part is made directly from 3D CAD model data without any
special tooling.
• The first commercial rapid prototyping process was brought on the market
in 1987.
• Nowadays, more than 30 different processes (not all commercialized) with
high accuracy and a large choice of materials exist.
• These processes are classified in different ways: by materials used, by
energy used, by lighting of photopolymers, or by typical application range.
• In the Rapid Prototyping process the 3D CAD data is sliced into thin
cross sectional planes by a computer.

• The cross sections are sent from the computer to the rapid prototyping
machine which build the part layer by layer.

• The first layer geometry is defined by the shape of the first cross
sectional plane generated by the computer.

• It is bonded to a starting base and additional layers are bonded on the

top of the first shaped according to their respective cross sectional
planes.

• This process is repeated until the prototype is complete.

Rapid prototyping is a group of
techniques used to quickly fabricate a
model of a physical part or assembly using
three-dimensional computer aided design
(CAD) data.
Construction of the part or assembly is
usually done using 3D printing or "additive
layer manufacturing" technology.
 How 3D Printing Works?
Step 1 – 3D model creation
First a 3D model of the object is created using CAD software or a 3D object scanner
Step 2 – STL file creation
CAD model is converted to a STL file to tessellate the 3D shape and slice it into
digital layers
Step 3 – STL file transfer
STL file is then transferred to the printer using custom machine software
Step 4 – Machine set up
Consumables are then loaded and the printer is set-up with printing parameters
Step 5 – Build
Printer builds the model by depositing material layer by layer
Step 6 – Part Removal
Part is then removed from the build platform and its support structure
Step 7 – Post processing
 ADDITIVE MANUFACTURING PROCESS

Step1 Produce a 3D model using computer-aided design(CAD) software.(CAD

software Ex. Solid Works, Pro/Engineer, CATIA and many more )

Step 2 Convert the CAD drawing to the .STL format.(many other formats
are .WRL and .VRML )

Step 3 Now the .STL model is sliced into thin layers through slicer software
(Cura, Slic3r, KISSlicer).This slicer software convert .STL file in to G-code file
which is understandable by 3D Printer.

Step 4 The AM machine must be properly set up prior to the build process. Such
settings would relate to the build parameters like the material constraints, energy
source, layer thickness, timings, etc.
 ADDITIVE MANUFACTURING PROCESS

Step 5 This G-code file upload to 3D Printer.

Step 6 According to G-code instructions 3D Printer start printing layer by layer form of
material which after become diffused together form the final object or product.

Step 7: Post processing

Once removed from the machine, parts may require an amount of additional cleaning up
before they are ready for use. Parts may be weak at this stage or they may have
supporting features that must be removed. This therefore often requires time and careful,
experienced manual manipulation.

Step 8: Application
Parts may now be ready to be used. However, they may also require additional treatment
before they are acceptable for use. 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 together with other mechanical or electronic
components to form a final model or product.
3 D Printer
General integration of an AM machine
 Distinction between AM and CNC machining
 AM shares some of its DNA with Computer Numerical Controlled machining
technology. CNC is also computer-based technology that is used to manufacture
products.

 CNC differs mainly in that it is primarily a subtractive rather than additive process,
requiring ablock of material that must be at least as big as the part that is to be
made.

 The fallowing parameters can be considered to distinguish AM and CNC machining

Material
Speed
Complexity
Accuracy
Geometry
Programming
Features that represent problems using CNC machining
Distinction between AM and CNC machining
Need for the compression in product
development,
History of RP systems
• The first working 3D printer was created in 1984
by Charles Hull of 3D Systems Corp

• He named the technique as Stereo lithography

and obtained a patent for the technique in 1986.
 1987
Carl Deckard, who was working at the University of Texas, filed a
patent in the US for the Selective Laser Sintering (SLS) RP process

 1989
Scott Crump, a co-founder of Stratasys Inc. filed a patent for Fused
Deposition Modelling (FDM).

 2005
Z Corp launched first high definition color 3D printer.
Throughout the 1990’s and early 2000’s a host of new technologies continued to be
introduced which saw the emergence of new terminology, namely Rapid Tooling (RT),
Rapid Casting and Rapid Manufacturing (RM) respectively.
 Survey of applications

Rapid Prototyping (RP) is a continuously evolving technology. RP

models are becoming widely used in many industrial sectors. Initially

conceived for design approval and part verification, RP now meets the

need for a wide range of applications from building test prototypes

with material properties close to those of production parts to

fabricating models for art and medical applications.

RP in five different application areas:

• Building functional prototypes,

• Patterns for castings,

• Medical models,

• Artworks

• Models for engineering analysis.

Functional Models
Patterns for castings
 Medical models
Operation planning. Using real size RP models of patients' pathologic regions, surgeons can
much more easily understand physical problems and gain a better insight into the operations to be
performed. RP models can also assist surgeons in communicating the proposed surgical
procedures to the patients.

Surgery rehearsal. RP models offer unique opportunities for surgeons and surgical teams to
rehearse complex operations using the same techniques and tools as during actual surgery.

Training. RP models of specimens of unusual medical deformities can be built to facilitate the
training of student surgeons and radiologists.

Prosthesis design. RP models can be used to fabricate master patterns which are then
replicated using a bio-compatible plastic material. Implants produced in this way are much more
accurate and cost effective than those produced employing conventional techniques.
Engineering Analysis Models

Visualisation of Flow Patterns. For example, SLA models were used to optimise the
cross-flow jacket of a V6 high-performance racing engine.

Thermo Elastic Tension Analysis (THESA). By employing the THESA method

[Gartzen et ai., 1998], RP models of real parts can be used on test rigs for structural analysis.

Photoelastic Stress Analysis. Photoelastic testing can be used to determine the

stresses and strains within physical parts under specific conditions.

Fabrication of Models for Wind Tunnel Tests. Despite recent advances in CAE
tools, the aerospace and automotive industries still rely on experimental wind tunnel test data
to verify the performance of new designs.
Classification of RP technology