What is Additive

Manufacturing?
INTRO
● Additive Manufacturing (AM)​ is an appropriate name to describe the technologies that
build 3D objects by adding layer-upon-layer of material, whether the material is plastic,
metal, concrete or one day…..human tissue.
● Common to AM technologies is the use of a computer, 3D modeling software
(Computer Aided Design or CAD)​, machine equipment and layering material. Once a
CAD sketch is produced, the AM equipment reads in data from the CAD file and lays
downs or adds successive layers of liquid, powder, sheet material or other, in a
layer-upon-layer fashion to fabricate a 3D object.
● The term AM encompasses many technologies including subsets like ​3D Printing,
Rapid Prototyping (RP), Direct Digital Manufacturing (DDM), layered
manufacturing and additive fabrication.
● AM application is limitless. ​Early use of AM​ in the form of Rapid Prototyping focused on
preproduction visualization models. More recently, AM is being used to fabricate
end-use products in aircraft, dental restorations, medical implants, automobiles,
and even fashion products.
While the adding of layer-upon-layer approach is simple, there are many
Applications of AM ​technology with degrees of sophistication to meet diverse needs including:
➔ a visualization tool in design.
➔ a means to create highly customized products for consumers and professionals alike
➔ as industrial tooling
➔ to produce small lots of production parts
➔ one day….production of human organs

Who Invented AM?

The earliest 3D printing manufacturing equipment was developed by Hideo Kodama of
the Nagoya Municipal Industrial Research Institute, when he invented two additive
methods for fabricating 3D models.

Additive Manufacturing Technologies

AM technologies can be broadly divided into three types.

The first of which is sintering whereby the material is heated without being liquified to
create complex high resolution objects. Direct metal laser sintering uses metal powder
whereas selective laser sintering uses a laser on thermoplastic powders so that the
particles stick together.

The second AM technology fully melts the materials, this includes direct laser metal
sintering which uses a laser to melt layers of metal powder and electron beam melting,
which uses electron beams to melt the powders.

The third broad type of technology is stereolithography, which uses a process called
photopolymerisation, whereby an ultraviolet laser is fired into a vat of photopolymer
resin to create torque-resistant ceramic parts able to endure extreme temperatures.

The seven major additive manufacturing

processes as classified per ASTM F42
are:

Process Description Technology

Photopolymerizat A vat of liquid photopolymer

ion resin is cured through ● Stereolithography
selective exposure to light (SLA)
(via a laser or projector). ● Digital Light
Processing (DLP)
This then initiates ● Continuous Liquid
polymerization and converts Interphase
the exposed areas to a solid Production (CLIP)
part.
 ● Scan, Spin, and
Selectively
Photocure (3SP)
Material Jetting Droplets of material are
deposited layer by layer to ● 3D Printing (3DP)
make parts. ● Multi-Jet Modeling
(MJM)
Common varieties include ● Drop on Demand
jetting a photo-curable resin (DOD)
and curing it with UV light, as
well as jetting thermally
molten materials that then
solidify at ambient
temperature.

This process was the origin

for the term “3D Printing”.

Binder Jetting Liquid bonding agents are

selectively applied onto thin ● Drop on Powder
layers of powdered material (DOP)
to build up parts layer by ● Powder Bed printing
layer.

The binders include organic

and inorganic materials. Metal
or ceramic powdered parts
are typically fired in a furnace
after they are printed.
Material Material is extruded through a
Extrusion nozzle or orifice in tracks or ● Fused Deposition
beads, which are then Modeling (FDM)
combined into multi-layer ● Fused Filament
models. Fabrication (FFF)

Common varieties include

heated thermoplastic
extrusion (similar to a hot
glue gun) and syringe
dispensing.

Powder Bed Powdered materials are

Fusion selectively consolidated by ● Selective Heat
melting them together using a Sintering (SHS)
heat source such as a laser or ● Direct Metal Laser
electron beam. Sintering (DMLS)
● Electron Beam
The powder surrounding the Melting (EBM)
consolidated part acts as ● Selective Laser
support material for Melting (SLM)
overhanging features. ● Selective Laser
Sintering (SLS).

Sheet Lamination Sheets of material are

stacked and laminated ● Selective Deposition
together to form an object. Lamination (SDL)
The lamination method can ● Laminated Object
be adhesives, ultrasonic Manufacturing (LOM)
welding, or brazing (metals). ● Ultrasonic Additive
Manufacturing (UAM)
Unneeded regions are cut out
layer by layer and removed
after the object is built.
Direct Energy Metal powder or wire is fed
Deposition into a melt pool which has ● Laser Metal
been generated on the Deposition (LMD)
surface of the part where it ● Electron Beam
adheres to the underlying Free-Form
part or layer. Fabrication (EBF3)
● Direct metal
The energy source is usually deposition (DMD)
a laser or electron beam. This ● Laser Engineered Net
process is essentially a form Shaping (LE
of automated build-up
welding.
PHASES

Examples of Additive Manufacturing

(AM)
1. SLA (STEREOLITHOGRAPHY)
Very high end technology utilizing laser technology to cure layer-upon-layer of photopolymer
resin (polymer that changes properties when exposed to light).
The build occurs in a pool of resin. A laser beam, directed into the pool of resin, traces the
cross-section pattern of the model for that particular layer and cures it. During the build cycle,
the platform on which the build is repositioned, lowering by a single layer thickness. The
process repeats until the build or model is completed and fascinating to watch. Specialized
material may be needed to add support to some model features. Models can be machined and
used as patterns for injection molding, thermoforming or other casting processes.
The material undergoes point-to-point solidification due to the photopolymerisation laser
being directed onto a 2D cross-section of the model (XY plane). The platform gradually
descends (Z plane) in accordance with the height of the layer defined

Advantages

1. Fast implementation of prototypes in early stages of product development

2. Single-stage production process produces smooth surfaces even without finishing
3. Low material consumption: non-hardened synthetic resin can be reused
4. Production of both flexible and rigid 3D objects
5. Cost-effective production
6. Customized coloring
7. Multi-part assemblies are possible
8. The quality and surface finish are good or very good. Great precisions and transparent
parts can be obtained.
Limitations:

● Depending on the material, components may be brittle

● Support structures can limit design freedom
● Components are only UV-resistant to a limited extent
● The equipment and materials are medium-high cost. They have problems to obtain
pieces with cantilevers or internal holes due to the difficulty of removing the supports.

2. FDM (FUSED DEPOSITION

MODELLING)
Process oriented involves use of thermoplastic (polymer that changes to a liquid upon the
application of heat and solidifies to a solid when cooled) materials injected through indexing
nozzles onto a platform. The nozzles trace the cross-section pattern for each particular layer
with the thermoplastic material hardening prior to the application of the next layer. The process
repeats until the build or model is completed and fascinating to watch. Specialized material may
be need to add support to some model features. Similar to SLA, the models can be machined or
used as patterns. Very easy-to-use and cool.
The wire is rolled around a coil and deposited using the thermal nozzle head that moves
in accordance with the plane (XY). The platform gradually descends (Z plane) in
accordance with the height of the layer defined.

Advantages
● Materials can be high strength
● It is cost-effective and waterproof
● It can use ABS material for its impact resistance and toughness
● Multiple material colors are available.
● Easy to use
● Quick speed for prototyping
● Can fulfill small quantities

DISADVANTAGES
● The extrusion head must continue moving, or else material bumps up; supports may be
required;
● Part strength is weak perpendicular to build axis; more area in slices requires longer
build times
● Temperature fluctuations during production could lead to delamination.
● Fused Deposition Modeling lays down layers much like hot glue coming out of a glue
gun. This often leads to ribbing, and you can see lines from each layer. An extra step of
polishing or sanding can be added to remove these lines.

3. MJM
Multi-Jet Modeling is similar to an inkjet printer in that a head, capable of shuttling back and
forth (3 dimensions-x, y, z)) incorporates hundreds of small jets to apply a layer of
thermopolymer material, layer-by-layer.
Advantages

● Very large variety of materials (from solid to rubbery)

● Transparent components
● Composite materials producible
● High precision and surface quality
● Fast process, since no heating and cooling times are needed
● Production of 3D-printed plastic injection molding cavities
● Good finishing possibilities

Limitations

● Lower temperature resistance

● Materials slightly brittle
● Materials not UV-resistant (embrittlement and discoloration possible)
 ● Restrictions in the geometric freedom, since support material must be
removable with water jet (accessibility, risk of damage)

4. 3DP OR Jet prototyping (JP)

This involves building a model in a container filled with powder of either starch or plaster based
material. An inkjet printer head shuttles applies a small amount of binder to form a layer. Upon
application of the binder, a new layer of powder is sweeped over the prior layer with the
application of more binder. The process repeats until the model is complete. As the model is
supported by loose powder there is no need for support. Additionally, this is the only process
that builds in colors.

The model is built on a bed full of powdered model material. A nozzle head injects an
agglutinate onto the surface of the bed and fuses the powder in accordance with the
geometry of the 2D cross-section of the model. The powder is added and levelled using
a roller. Once the process has been completed, the excess powder is sucked off the
bed leaving the model clean. The model then has to be cured (hardened) using different
coatings
ADVANTAGES
● Flexible Design
● Rapid Prototyping
● Print on Demand
● Strong and Lightweight Parts
● Fast Design and Production
● Minimising Waste
● Cost Effective
● Ease of Access
● Environmentally Friendly
● Advanced Healthcare

DISADVANTAGES
● Limited Materials
● Restricted Build Size
● Post Processing
● Large Volumes
● Part Structure
● Reduction in Manufacturing Jobs
● Design Inaccuracies
● Copyright Issues

5. SLS (SELECTIVE LASER

SINTERING)
Somewhat like SLA technology Selective Laser Sintering (SLS) utilizes a high powered laser to
fuse small particles of plastic, metal, ceramic or glass. During the build cycle, the platform on
which the build is repositioned, lowering by a single layer thickness. The process repeats until
the build or model is completed. Unlike SLA technology, support material is not needed as the
build is supported by unsintered material.

A layer of powder is laid down and a CO​2​ laser sinters it at the points selected on a 2D
cross section of the model (XY plane). The platform gradually descends (Z plane) in
accordance with the height of the layer defined

ADVANTAGES

● Excellent layer adhesion.

● Ideal for dyeing

● A distinct advantage of the SLS process is that because it is fully self-supporting,

it allows for parts to be built within other parts in a process called nesting – with

highly complex geometry that simply could not be constructed any other way.

● Parts possess high strength and stiffness

● Good chemical resistance
 ● Various finishing possibilities (e.g., metallization, stove enameling, vibratory
grinding, tub coloring, bonding, powder, coating, flocking)
● Fastest additive manufacturing process for printing functional, durable,
prototypes or end user parts.
● Complex parts with interior components, channels, can be built without
trapping the material inside and altering the surface from support removal.

DISADVANTAGES

● Porous and brittle

● Prone to shrinkage and warping

● Messy

● Produces a lot of waste

6.LAMINATED MANUFACTURING

Invented in 2003 by MacCormack, SDL must not be confused with laminated object
manufacturing (LOM) technology. LOM uses a laser, laminated paper and an adhesive
that fixes the model and support material.
The SDL technique works by depositing an adhesive in the area required, both of the
model and the support, and a blade that cuts the outline of the layer.

ADVANTAGES
● Faster print time, but post processing will be required
● Ability to integrate as hybrid manufacturing systems
 ● Ease of material handling
● Ceramic (CAM-LEM) and composite fibre (SLCOM) parts can be
manufactured
● OEM components, such as sensors, wires, etc., can be embedded into the
part during the layering stage. Highly depends on the sheet lamination
technique and material used
● Relatively low cost as it uses standard material
● No support structures necessary

DISADVANTAGE
● Layer height cannot be changed without changing the sheet thickness
hence part resolution is linked to sheet thickness along the vertical build
axis
● Finishes can vary depending on paper or plastic material but may require
post processing to achieve desired effect
● Limited material options available
● It can be time consuming and difficult to remove the excess material after
the laminating phase and it generates a lot of waste compared to other
AM methods
● Hollow parts (internal voids and cavities) are difficult to produce in some
types of sheet lamination processes, such as “bond then form”
● Bonding strength will depend on the laminating technique used and, in
some cases, adhesive bonds are not good enough for long term use of the
product strength and integrity
● Material waste can also be high if the part being made is smaller than the
build area or the sheet size
7. INJECTION POLYMERISATION

A head with thousands of injectors deposits drops of liquid resin that are hardened
using two UV ray lights fitted on the sides of the selfsame head. Two materials can be
used simultaneously (bi-material pieces)

ADVANTAGES
● Flexible Printing Setup
● Good Accuracy, Decent Surface Finish
DISADVANTAGES
● Lacking in Strength and Durability, Still Affected By UV Light After Print
● Best for Display and Quick Decoration, Not For Heavy Use