Additive Manufacturing;

Present And Future

Presented by, Stephin Abraham Sabu S7 ME B Roll No. 48

Guided by, Prof. Aneesh K S Mechanical Dept.

2

CONTENTS1. Introduction2. What is additive manufacturing?

Functional principle Advantages & disadvantages Applications

3. AM Processes4. Present conditions5. AM - Future Aspects6. Gaps & needs7. Recommendations8. Conclusion

3

IntroductionManufacturing is a process in which raw materials are transformed into finished goods.

Additive Manufacturing• Technology that can make anything.• Eliminates many constraints imposed by conventional

manufacturing • Leads to more market opportunities.• Increased applications such as 3D faxing sender scans a

3D object in cross sections and sends out the digital image in layers, and then the recipient receives the layered image and uses an AM machine to fabricate the 3D object.

4

What is Additive Manufacturing? The process of joining materials to make objects from three-

dimensional (3D) model data, usually layer by layer Commonly known as “3D printing” Manufacturing components with virtually no geometric limitations or

tools. AM uses an additive process Design for manufacturing to manufacturing for design Distinguished from traditional subtractive machining techniques

5

Functional principle The system starts by applying a thin layer of the powder material to the

building platform. A powerful laser beam then fuses the powder at exactly the points

defined by the computer-generated component design data. Platform is then lowered and another layer of powder is applied. Once again the material is fused so as to bond with the layer below at

the predefined points.

6

ADVANTAGES Freedom of design Complexity for free Potential elimination of tooling Lightweight design Elimination of production steps

DISADVANTAGES Slow build rates High production costs Considerable effort required for application design Discontinuous production process Limited component size.

7

ApplicationsAM has been used across a diverse array of industries, including;

Automotive Aerospace BiomedicalConsumer goods and many others

8

AM processes are classified into seven categories

1) Vat Photopolymerisation/Steriolithography2) Material Jetting3) Binder jetting4) Material extrusion5) Powder bed fusion6) Sheet lamination7) Directed energy deposition

9

Vat photopolymerization/Steriolithography• Laser beam traces a cross-section of the part pattern on

the surface of the liquid resin• SLA's elevator platform descends• A resin-filled blade sweeps across the cross section of the

part, re-coating it with fresh material• Immersed in a chemical bathStereolithography requires the use of supporting structures

Material Jetting  • Drop on demand method• The print head is positioned above build platform• Material is deposited from a nozzle which moves

horizontally across the build platform • Material layers are then cured or hardened using

ultraviolet (UV) light• Droplets of material solidify and make up the first layer.• Platform descends• Good accuracy and surface finishes

10

11

Binder Jetting• A glue or binder is jetted from an inkjet style print head • Roller spreads a new layer of powder on top of the previous

layer• The subsequent layer is then printed and is stitched to the

previous layer by the jetted binder• The remaining loose powder in the bed supports overhanging

structures

12

Material Extrusion/FDM• Fuse deposition modelling (FDM)• Material is drawn through a nozzle, where it is heated and is then

deposited layer by layer• First layer is built as nozzle deposits material where required onto

the cross sectional area.• The following layers are added on top of previous layers.• Layers are fused together upon deposition as the material is in a

melted state.

13

Powder Bed Fusion• Selective laser sintering (SLS)• Selective laser melting (SLM)• Electron beam melting (EBM)No support structures required

PROCESS

• A layer, typically 0.1mm thick of material is spread over the build platform.

• The SLS machine preheats the bulk powder material in the powder bed

• A laser fuses the first layer• A new layer of powder is spread.• Further layers or cross sections are fused

and added.• The process repeats until the entire model

is created.

Sheet Lamination• Metal sheets are used• Laser beam cuts the contour of each layer• Glue activated by hot rollers

14

PROCESS1. The material is positioned in place

on the cutting bed.2. The material is bonded in place, over

the previous layer, using the adhesive.

3. The required shape is then cut from the layer, by laser or knife.

4. The next layer is added.

15

Directed Energy Deposition• Consists of a nozzle mounted on a multi axis arm• Nozzle can move in multiple directions• Material is melted upon deposition with a laser or electron

beam

PROCESS1. A4 or 5 axis arm with nozzle moves

around a fixed object.2. Material is deposited from the nozzle onto

existing surfaces of the object.3. Material is either provided in wire or

powder form.4. Material is melted using a laser, electron

beam or plasma arc upon deposition.5. Further material is added layer by layer

and solidifies, creating or repairing new material features on the existing object.

16

Present Condition & TrendsTechnology And Research• The model data, usually in stereolithography (STL) format, is first

decomposed into a series of 2D, finitely thick cross sections, which are then fed into an AM machine.

• Used directly and indirectly to produce prototype parts • Reduce manufacturing and product costs

University–Industry Collaboration and Technology TransferMore and more companies have begun using AM technology to;

• Reduce time-to-market• Increase product quality• Improve product performance• Costs

17

• Metal-based AM processes have recently emerged in industrial applications for manufacturing items such as automotive engines, aircraft assemblies, power tools, and manufacturing tools including jigs, fixtures, and drill guides

Education And Training• Educating the general public about AM empowers people to build

what they dream.• Formal AM education has already been integrated into curricula at

different levels.• Educational materials on rapid prototyping have long been a part of

manufacturing engineering courses

18

AM - Future AspectsTechnology And Research• “ Third industrial revolution “• The cost effective mass customization of complex products • Reduced material waste and energy consumption• Adapt new product designs without the additional expenses• In the biomedical field, AM can be used to fabricate tissue scaffolds

that are biocompatible, biodegradable, and bio-absorbable

Education & Training• AM holds great potential for promoting science, technology,

engineering, and mathematics (STEM) education• The availability of low-cost 3D printing equipment is creating the

opportunity for AM-enabled, hands-on labs in primary, secondary, and postsecondary schools across the nation

19

Gaps & NeedsTechnology and Research

20

Material• Intensive materials research and development is needed• In metallurgy, it takes about 10 years to develop a new alloy, including the

determination of various critical properties such as fatigue strength. This time frame also applies to developing new materials for AM

• Even with existing materials, advancements are neededDesign• Various AM-oriented design tools must be developed• CAD systems should be re-invented to overcome its limitationsModeling, Sensing, Control, and Process Innovation• Difficult to predict the microstructures and fatigue properties resulting

from AM processes• The sensing of AM processes may require fast in situ measurements of the

temperature, cooling rate, and residual stressCharacterization and Certification• Real production environments and practices are much more rigorous

than those for prototyping purposes.• The existing AM systems are still predominantly based on rapid

prototyping machine architectures

21

University–Industry Collaboration and Technology Transfer.• To compete with conventional mass production processes, AM

technology must advance significantly in order to drastically reduce the cost of fabrication, improve the performance of fabricated parts

• The price of materials for AM would need to drop substantially in order to achieve sufficient return on investment to make AM for mass production a reality

22

Hype Curve

23

Education & Training While numerous AM education resources and training materials are

available, there is still no readily applicable, proven model for AM education and training

Taking full advantage of AM will require;• Educating the current workforce• Recruiting a new generation of students• Developing proper design tools

24

RecommendationsTechnology and Research.

Materials• Development of new materials for AM processes• Formation and mixing of materials in desired forms and with desired propertiesDesign• Methods and tools for simultaneous multifunctional• Product design and AM process designModeling• Robust physics-based mathematical models of temperature, stress etc.• Prediction of microstructures and fatigue properties resulting from extreme heating

and cooling rates in AM processesSensing and control• Fast-response sensors for detecting defects and phase transformations• Integrated real time sensing and closed-loop control of AM processes• The production costs, manufacturing time, and part defects must be reduced

drastically in order for AM to become hugely successful.

25

University–Industry Collaboration and Technology Transfer• Collaborations incentivized by federal funding programs• Increased federal research and development (R&D) support

Education and Training

Teaching FactoryIn the teaching factory, students are exposed directly to a manufacturing enterprise where they design products to meet customer needs and manufacture their designed products for the market.

Other Training Efforts Promotion of public awareness Use of the Internet Establishment of publicly accessible AM facilities

26

CONCLUSION• The process of joining materials to make objects from three-

dimensional (3D) model data, usually layer by layer• Traditional subtractive machining techniques rely on the removal of

material by methods such as cutting or milling• Has many advantages over traditional manufacturing processes• Seven processes of AM• AM is on the verge of shifting from a pure rapid prototyping

technology • Manufacturing metal components with virtually no geometric

limitations or tools offers new ways to increase product performance or establish new processes and revenue streams

27

ReferencesBase Journal ; Additive Manufacturing: Current State, Future Potential, Gaps and Needs, and Recommendations 

1. ASTM, 2009, ASTM International Committee F42 on Additive Manufacturing Technologies, ASTM F2792–10 Standard Terminology for Additive Manufacturing Technologies, ASTM, West Conshohocken, PA. 

2. Wohlers Associates, Inc., 2013, Wohlers Report 2013: Additive Manufacturing and 3D Printing State of the Industry, Wohlers Associates, Fort Collins, CO. 

3. Bourell, D. L., Beaman, J. J., Leu, M. C., and Rosen, D. W., 2009, “A Brief History of Additive Manufacturing and the 2009 Roadmap for Additive Manufacturing: Looking Back and Looking Ahead,” Proceedings of RapidTech 2009: US-TURKEY Workshop on Rapid Technologies, Istanbul, Turkey, Sept. 24–25, pp. 1–8.

4. Google5. Wikipedia

28

THANK YOU