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Additive Manufacturing

Anant Sadarjoshi

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New Industry Trends

IMAGINE & SHAPE THE WORLD WE LIVE IN

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New Machines/New

Materials

are changing the way to produce

Print a composites

chassis

Metal cladding for

repair

Metallic Powder

Bed

enabling new ways to

design

New materials

Functionally graded

material

3-D printed antenna

with embedded

electronic wires

New topologies

Titanium buckle

New Assembly

structures

Fuel Nozzle

THE NEW WORLD OF MAKING IS IN PROGRESS

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Function-Driven Generative Designer Role (GDE)

3DMaster Conceptual Designer

Mechanical Tooling Designer

Mechanical Designer

Mechanical & Shape Designer

Sheetmetal Designer

Plastic Mechanical Designer

Core Engineering Base Roles

Function-Driven Generative Designer

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ADDITIVE MANUFACTURING : MANY APPLICATIONS

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A SEGMENTED MARKET NURTURING MULTIPLE USE CASES

C. BIO PRINTING

BUSINESS BY PEOPLE

A. INDUSTRIAL USE CASE D. 3D PRINTING BY MAKERSB. MASS CUSTOMIZATION

Rapid Prototyping

Tailor made goods to fit

morphological expectation

Product customization &/or

prototyping

Small volume production

Innovative design & manufacturing

PEOPLE IN BUSINESS

consumers

& hobbyists

startups projects

Academic learning

artists, craftsmen &

creators

WHAT do Users value the most?

Faster & cheaper

development cycle

Limitless design

possibilities

Enhanced product

performance Master Mfg

process

Quick & affordable

production

Parametrized

process & products

- Easy & intuitive

customization Local manufacturingCheap & fast

deliveryEasy 3D capture &

creationIntuitive & self

learningSocial experience &

open ecosystem

Bioprinters• Regenovo

• Oranovo

3D bioprinted• Cartilage

• Blood vessels

• Organs

Master Mfg

process

Easy 3D capture &

creationEnsure quality & tracability

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WITH A MULTITUDE OF PROCESSES & MACHINES

Technology Processes

Powder Bed Fusion (Thermal energy selectively fuses regions of a

powder bed )

Processes : Selective Laser Melting, Direct

Metal Laser Sintering, Electron Beam

Melting, …

Machines : EOS, Renishaw, Arcam, BeAM…

Processes : Selective Laser Sintering,

Selective Laser Printing, …

Machines : EOS, 3D Systems, Renishaw

Processes : Selective Laser Sintering

Machines : Graphite AM, CFR Group

Binder Jetting (A liquid bonding agent is deposited to join

powder materials)

Processes : Binder Jetting

Machines : ExOne

Processes : 3D Printing

Machines : Voxel Jet

Processes : 3D Printing

Machines : 3D Systems, ExOne

Directed Energy Deposition (Focused thermal energy fuses materials as

they are deposited)

Processes : Laser Engineered Net Shape,

Laser Deposition, …

Machines : Trumpf, DMG, Optomec

Material Jetting (Droplets of Build Materials are selectively

deposited)

Processes: PhotoPolymerization Jetting

Multi Jet Modeling, Multi-Jet Fusion

Machines : Stratasys (Objet, Solidscape),

3D Systems, HP

Processes : Wax Thermo Jet

Machines : 3D Systems

Photo Polymerization (Liquid photopolymer is selectively cured by

light-activated polymerization)

Processes : StereoLithography, Digital Light

Processing

Machines : 3D Systems, Envisiontec

Material Extrusion (Melted Materials are dispensed through a nozzle)

Processes : Fused Deposition Modeling

Machines : Stratasys

Processes: Composites AM

Machines : BAAM (Big Area Additive

Manufacturing)

Sheet Lamination (Sheets of material are bonded to form an object)

Processes : Laminated Object

Modeling, Ultrasonic Consolidation

Machines : MCOR, Fabrisonic

Processes : Laminated Object

Modeling, Paper Lamination Technology

Machines : MCOR

Technology Metal Polymer Other Materials

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THE NEW WORLD TO IMAGINE, DESIGN AND MAKENew Machines/New

Materials

New ways to produce

Bio-printing of

cartilage

New ways to design

New topologies

Titanium buckle

New Assembly

structures

Metallic cladding for

repair

MX3D bridge printing

New Eco-SystemNew Economy of Contribution

Machine Providers

Material Providers

Labs/ AcademicsEngineering Experts

Service Providers

Manufacturing Experts

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STILL WITH MANY CHALLENGES TO SOLVE

• Explore new type of

materials

• Master their use &

properties

• Understand influence

of process on

microstructure

• Health and safety issues

• Remove barriers between

Designers, Analysts

• Quickly Deliver topology-

optimized shapes

• Model more organic shapes

• Standardize Design rules for

Additive Manufacturing (DFAM)

• Overcome High Cost of

manufacturing

• Competitive Cycle time

• Process repeatability for

up-scaling

• Standard for quality

control

• Ensure that part

can be produced

• Provide appropriate

Repair Services

• Define and simulate

upfront the

deposition strategy

• Standardize

in-process

inspection &

quality control

• Reduce post-

processing steps

by improving

process control

DesignMaterial ManufacturingPreparation Shopfloor

Simulation

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FUNCTION-DRIVEN GENERATIVE DESIGN2

Innovative Designs

• Organic shapes

• Function integration

• Assembly Optimization

• Performance improvement

• Weight reduction

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Ceramics

Metals

Plastics

OthersSteel, bronze, gold, silver,

titanium… Composites, Food, biocells,

bioplastics…

Nylon, rubber like, resin,

photopolymers…

Glass, Quartz, silica

A.Materials

B.Processes to manufacture the materials

Free your mind for

innovate design …

…..with materials & processes that will make them feasible

Additive Manufacturing | Opens new design possibilities

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1. A layer of material is spread over the build platform by the powder re-coater.

2. A laser fuses the first layer of the model.

3. A new layer of powder is spread across the previous layer using a roller.

4. Further layers are fused and added.

5. The process repeats until the entire model is created. Loose, unfused

powder is remains in position but is removed during post processing.

Additive Manufacturing | Powder Bed Fusion process

Powder Bed Fusion main techniques:

1. Direct Metal Laser Sintering (DMLS)

2. Electron Beam Melting (EBM)

3. Selective Laser Melting (SLM)

4. Selective Heat Sintering (SHS)

5. Selective Laser Sintering (SLS)

Step by Step

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MANUFACTURING PROCESS DEFINITION & SIMULATION3

Process & Quality control

• Program the machine &

plan the production,

ensuring :• Part Quality (as manufactured

= as designed )

• Repeatability

• Productivity

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