Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

ME5011 – AM Process
Chain
Senthilkumaran Kumaraguru
Lecture 4

1 ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

Additive Manufacturing

• A fabrication method in which parts are built by adding material

layer by layer under computer control using the data from a CAD
model.

STEP #1 STEP #2 STEP #3 STEP #4

CAD model creation Tessellation & Slicing Part fabrication Part finishing

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

AM Process chain
• Creation of Geometric Model
• Tessellation
• Slicing
• Generation of Laser Scanning Path
• Part Fabrication
• Post Processing

4
ME5011 – Design for Additive Manufacturing
Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

Generic process of CAD to part,

showing all eight stages

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

Support structures
• Temporary structures added to a
3D model during printing.
• Provide essential support to
overhanging
features, bridges, and intricate
details.
• Removed after printing to reveal
the final object.

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

Why Use Support Structures?

• Prevent Deformation:
• Overhanging features without support
would droop or collapse under their
own weight during printing.
• Maintain Accuracy:
• Support structures ensure precise
printing of intricate details and
complex geometries.
• Improve Surface Quality:
• Certain support materials leave
minimal marks on the finished object,
minimizing post-processing.

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

Types of Support Structures

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

Slanting surfaces

ME5011 – Design for Additive Manufacturing

 Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

Additive Manufacturing
Natural Supports Artificial Supports
• Natural Supports
• PBF (polymers) • PBF (Metals)
• Artificial Supports
• BJP (Polymers • MJ, ME, VP, DED
and metals)
• DED (Multi-axis)
• Sheet
Lamination
Additive
Manufacturing

Vat Powder Material Material Binder Sheet Directed Energy

Polymerization Bed Fusion Extrusion Jetting Jetting Lamination Deposition

11
ME5011 – Design for Additive Manufacturing
Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

End of Lecture 5
Any Questions?

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

ME5011 – Process
Planning for AM
Senthilkumaran Kumaraguru
Lecture 5

13 ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

End of Lecture 5
Any Questions?

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

ME5011 – Introduction
to AM – Part 2
Senthilkumaran Kumaraguru
Lecture 3

19 ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

Tessellation

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

Orientation

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

Slicing

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

End of Lecture 6
Any Questions?

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

ME5011 – Build preparation printing

the part.
Senthilkumaran Kumaraguru
Tutorial 3

24 ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

Build Preparation Software

• PBF: Materialize Magics:
• https://youtu.be/diuxq0nKO6k?si=_bVJUiJx_3nx3FYj
• VAT Photopolymerization: Materialize Magics:
• https://youtu.be/TZ_Qps9PboY?si=Xo4SOQxbkmgqIDXJ
• Fused Filament Fabrication: Cura
• https://youtu.be/SmtMj6i-pB0?si=Qiuf-reeWYr5Gmld
• Polyjet: https://www.youtube.com/watch?v=RU7uWuGpHBA
• Binder jetting: Autodesk Netfabb
• https://youtu.be/5l4V9xrUATI?si=TZD2s0yv1qakizZZ

ME5011 – Design for Additive Manufacturing

Design for Additive Manufacturing Laboratory, Department of Mechanical Engineering, IIITDM Kancheepuram

End of Tutorial 2
Any Questions?

ME5011 – Design for Additive Manufacturing