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    Vishweshwar Hosmath
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    Additive manufacturing (AM), also known as 3D printing or rapid prototyping, is a process that transforms a CAD model into a physical object by layer-by-layer deposition of material. There are various ways to classify AM technologies, including by starting material state (liquid, solid, or powder-based), dimensions of input material, output material type, and application. Additive manufacturing techniques like fused deposition modeling (FDM) and selective laser sintering (SLS) can help compress product development timelines through rapid prototyping. FDM uses thermoplastics like ABS that are deposited through a heated nozzle, while SLS uses a laser to sinter powdered materials like nylon or metals.

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    Additive manufacturing (AM), also known as 3D printing or rapid prototyping, is a process that transforms a CAD model into a physical object by layer-by-layer deposition of material. There are various ways to classify AM technologies, including by starting material state (liquid, solid, or powder-based), dimensions of input material, output material type, and application. Additive manufacturing techniques like fused deposition modeling (FDM) and selective laser sintering (SLS) can help compress product development timelines through rapid prototyping. FDM uses thermoplastics like ABS that are deposited through a heated nozzle, while SLS uses a laser to sinter powdered materials like nylon or metals.

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    19 views32 pages

    3D Printing

    Uploaded by

    Vishweshwar Hosmath
    Additive manufacturing (AM), also known as 3D printing or rapid prototyping, is a process that transforms a CAD model into a physical object by layer-by-layer deposition of material. There are various ways to classify AM technologies, including by starting material state (liquid, solid, or powder-based), dimensions of input material, output material type, and application. Additive manufacturing techniques like fused deposition modeling (FDM) and selective laser sintering (SLS) can help compress product development timelines through rapid prototyping. FDM uses thermoplastics like ABS that are deposited through a heated nozzle, while SLS uses a laser to sinter powdered materials like nylon or metals.

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    of 32

    WHAT IS ADDITIVE

    MANUFACTURING (AM) ?

    “Additive Manufacturing” is an interesting technology


    that rapidly transforms a CAD model into a real
    object by layer to layer deposition of materials.

    The term "3D printing“ or ‘’Rapid Prototyping” is


    increasingly used as a synonym for
    Additive manufacturing.
    CLASSIFICATION OF RP SYSTEMS
    There are various ways by which RP technologies can
    be classified

    Based on the starting/input state:-

    Liquid Based : SLA, DLP

    Solid Based : Pellets, wires, Sheets, FDM, LOM, MJM

    Powder based : SLS, 3DP, LENS, EBM, SLM, DLMS


    Based on Dimensions of input material:-

     0 dimension : Powder based


     1 dimension : Wire/Filament based
     2 dimension : Sheet Based

    Based on the output material:-

     Metal Based printers : SLM, DLMS, EBM


     Polymer Based Printers : FDM, SLA
    (ABS, PA6, PLA, HDPE, LDPE)
     Ceramic Based Printers

    Based upon the application :-

     Normal Printers : FDM, SLM, SLA,


     Office Modellers : MJP, GeneSys XS printers, Sanders Model Makers,
    HP printers
    Classification of Additive Manufacturing
    NEED FOR TIME COMPRESSION IN
    PRODUCT DEVELOPMENT
     Due to rise in international competition, market globalization, and
    the complexity of industrially manufactured products, a demand for
    fast delivery is seen

     It has become important for a new product to reach the market


    swiftly, before the competitors

     For this to happen, many of the processes like design, testing,


    manufacturing, inspection, marketing has to squeezed or compressed

     This approach is called Time Compression Engineering

     One of such tool is Rapid prototyping


    Conceptual Detail Engg.
    Prototyping Tooling Production
    design Design Analysis

    CONVENTIONAL MANUFACTURING

    CONCEPTUAL DESIGN
    CAD MODELLING
    DETAIL DESIGN

    ENGINEERING
    FEA
    ANALYSIS TIME SAVE

    PROTOTYPING

    TOOLING
    RP
    PRODUCTION

    MARKETING

    TIME

    FIGURE :- TIME COMPRESSION WITH THE HELP OF RP


    Over the wall syndrome
    FDM AND SLS TECHNIQUE
     Fused Deposition Modelling

    Principle

    Operation

    Construction

    Materials

    Process parameters

    Advantages and Limitation


    FUSED DEPOSITION MODELLING (FDM)

    Icing on a cake

    Courtesy:- Mr. D. Chandramohan, Dr. K. Marimuthu, Rapid prototyping/rapid tooling – a over view
    And its applications in orthopaedics, International Journal of Advanced Engineering Technology
    MATERIALS
     Most popular material is ABS. ABS stands for
    Acrylonitrile Butadiene Styrene.

     ULTEM material –Stratasys

     Second most popular material is PLA. PLA stands for


    Poly Lactic Acid. Biodegradable. Made from sugarcane.

     Nylon (PA6) is also becoming famous now

     HIPS, PETG, HDPE, LDPE can also be used


     PEEK is becoming very famous nowadays for medical
    applications

     FDM works best with polymers that are Amorphous in


    nature as compared to crystalline polymers.

     Not all polymers are FDM printable.

     Materials are ABS, PLA, PETG, HIPS, LDPE, Nylon and


    PEEK.

     Virgin polymers-------Composite polymers-------Metal


    reinforced composite polymers
    MATERIALS FOR FDM PRINTING

    Materials/ ABS PLA HIPS PA6 PETG PEEK


    Properties (Nylon)
    Tensile Strength 34 65 22 42.2 55.5 100
    (Mpa)
    Tg (0C) 110 60 89 47 80 143
    Tm (0C) 130 170 180 215 250 343
    Bio-degradable No Yes No No No No

    Soluble in Acetone Ethyll- Di- NA NA NA


    acetate Lemonine
    PROCESS PARAMETERS
    1) Layer Thickness
    •This setting controls the height of the slices.
    • It has been established by numerous researchers that layer
    thickness does affect the surface finish of the parts produced
    Layer
    Thickness

    •L.T increases Surface Roughness Increase


    •L.T. Increases Total Build time Decreases
    2) Infill Percentages
    •This setting controls the density of internal fills of the parts produced

    Infill % increases Build Time increases


    Infill % increases Strength increases

    Infill

    Straight pattern Orthogonal pattern Zig Zag pattern


    3) SUPPORT STRUCTURES
    OVERHANGING STRUCTURES REQUIRES SUPPORT STRUCTURES. GENERALLY
    GREATER THAT 15 DEGREES PRINT WILL REQUIRE SUPPORT.

    Support

    Support can be:-


    •Coarse
    •Rough
    •Medium
    •Dense
    •Fine
    •Ultra
    4) Part Orientation
    5) SPEED, BED TEMPERATURE AND NOZZLE
    TEMPERATURES

     Speed usually set is 60 mm/sec

     Bed Temperature set is 110 degree Celsius

     Nozzle temperature set is 220 degree Celsius


    ADVANTAGES AND LIMITATIONS OF
    FDM
    Advantages
     The process is clean, simple, easy to use and operate
     No wastage of materials
     Lack of expensive lenses, lasers as seen in Photo-polymerisation or
    Sintering Techniques

    Limitations
     FDM machines are costly
     Because of circular nozzles sharp edges cannot be made easily
     Low speed and accuracy
     Parts are An-Isotropy in nature (Z direction )
     Dimensional accuracy is bad
     Surface finish is bad
    THE STAIR CASE EFFECT - RESPONSIBLE
    FOR DIMENSIONAL INACCURACY AND BAD
    SURFACE FINISH
    SELECTIVE LASER SINTERING (SLS)
    PROCESS (DMLS) (PBF) (EBM)
     Selective Laser Sintering is an powder based RP technique which
    directly creates a physical model out of a CAD model by sintering

     Developed by Dr. Joe Beaman and his student at the university of


    Texas at Austin, USA. Commercialised by DTM corp.

     Principle - the principle on which SLS works is SINTERING.


     Sintering depends upon the free energy (G) of the metal powders

     Free energy (G) = Volume of powders (V)/ Surface area of


    powders(A)

     As V decreases or A increases G decreases

     As G decreases, Sintering rate increases

     Hence smaller the particles, greater will be the sintering process.


    • The apparatus consists of three tanks – feeder tank, build up tank and excess powder
    take up tank.

    •Thin layers of powders (0.075-0.1 mm thick) are spread across the build area using a
    counter-rotating powder levelling roller.

    •The part building process takes place inside an enclosed chamber filled with nitrogen gas
    (prevents oxidation).

    •The powder in the build platform is maintained at high temperature


    (below the melting temperature)
     Infrared heaters are placed above the build platform to maintain the elevated
    temperature

     This minimises the laser power requirement as well as warping

     Co2 laser is used

     A focussed CO2 laser beam is directed onto the powder bed and is moved using
    galvanometers.

     Supporting powder remains loose and serves as support for subsequent layers.

     After completion a layer, the build platform is lowered by one layer thickness and
    a new layer of powder is laid and levelled using the counter rotating roller.

     The beam scans the subsequent slice cross section.

     This process repeats until the complete part is built.

     About 70% compaction is achieved.


     https://formlabs.com/blog/what-is-selective-laser-
    sintering/
    Material used :

    Polymers and Composites:- Polyamide (nylon), PEEK, Polysterene, PLA etc.

    Metals and Composites :- Steel, Ti and alloys, Ni based alloys, aluminium alloys etc.

    Ceramics and Composites :- Alumimum oxide and Titanium oxide

    Fusion Mechanisms :

    Solid State Sintering : The image above

    Liquid phase sintering : Partial melting Ex:- Groundnuts and Jagery

    Chemically induced binding : use of thermally active chemicals. Used for binding
    ceramics

    Full melting : melting, PA6.


    Partial melting

    Selective Laser Sintering, Selective Laser Melting, Direct Metal Laser Sintering,
    Electron Beam Melting etc.. Are the other names for the same technology.
    PROCESS PARAMETERS
    In PBF, process parameters can be lumped into four categories:

    (1) laser-related parameters (laser power, spot size, pulse duration,


    pulse frequency, etc.)

    (2) Scan related parameters (scan speed, scan spacing, and scan
    pattern)

    (3) Powder-related parameters (particle shape, size, and distribution,


    powder bed density, layer thickness, material properties, etc.), and

    (4) Temperature-related parameters (powder bed temperature, powder


    feeder temperature, temperature uniformity, etc.).
    PROCESS BENEFITS AND DRAWBACKS
     Wide range of materials

     Different type of metals can be processed

     No support structure required and post processing

     Accuracy and surface finish of powder-based AM


    processes are typically inferior to liquid-based processes
    (depends on powder size)

     More total time in construction

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