Laser-based Additive Manufacturing

Processes

Prof. Stefan Dimov

Department of Mechanical Engineering

Laser-Based Manufacturing Stream

MSc/MEng Advanced Manufacturing Module
 Beam Delivery Systems: Key Components 2

Adjustable mirrors
(optional)
Collimator Beam Expander
Laser
(optional) (optional)

Multi-Axes
X-Y Scan Head Z-module
Robotic Hand
(optional) (optional)
(optional)

Focusing Cutting/Dep
Lens osition Head Many possible configurations & applications, e.g.:
(optional) (optional) q Laser ►Collimator► Cutting Head ►XYZ stage
►Workpiece = cutting
Workpiece q Laser ►Adjustable Mirrors ►X-Y Scan head ►Power
A&C rotary stages bed/UV sensitive resins ►Focusing Lens ►Z stage = AM
(optional) q Laser ►Adjustable Mirrors ►Z-module ►X-Y Scan head
XYZ positional stages ►Focusing Lens ► Workpiece = milling/marking/welding
(optional) q …
 3
Flat Field Scanning Lenses (Telecentric)
Scanning Lens

ρ=2.9)

DOF (a tolerance for texturing/structuring curved

Z tool surfaces)
coordinate Beam spot size (dB ) (Ø of the beam spot)
defined
f - focal length
D - input beam diameter
4 λ M2 f M2 - beam mode
dB = λ – wavelength
πD
ρ – tolerance factor depending on
2
8 λ M2 æfö the increase of Ø of the focus from its
DOF = ρ 2 - 1ç ÷ min value at the waist (5% -> 1.05)
π èDø
 X-Y Scan Head + Z module 4

XY Scanner

Z module

Telecetric lens (mm) 100 167 254

Focusing Volume (mm) 35x35x6 60x60x10 120x120x20
Min spot size (μm) 14 23 35
 5
Lecture Outlines

q Classification of laser-based additive

manufacturing processes
q Technical capabilities
q Material and process optimisation issues
q Applications
q Challenges
q Conclusions
 Additive Manufacturing 6

Additive Manufacturing (AM)

also called “Net Shape
Manufacturing”, “Layer Based
Manufacturing”, “Rapid
Prototyping”, “Rapid
Manufacturing”, etc.
AM is a “tool box” that includes a number of layer based manufacturing
techniques to produce components in numbers from 1 to 100,000+
q sustainable manufacturing technology
q scalable process (parallel manufacture) for on demand manufacture
q offers design freedom (new “design for manufacture” considerations) to
produce part of any complexity
q no need to “freeze” the design and short lead time (no tooling)
q variety of materials available (plastic, ceramic, metals and functionally
gradient materials)
 Manufacturing Processes: Three Group 7

Forming

Additive
Injection Manufacturing
Moulding Casting
Scallan, P. (2003) Process Planning - The Design/Manufacture Interface
 8
Technology and Application Level Definitions

Understanding Additive Manufacturing, Andreas Gebhardt, 2012

 Classification 9

Laser-Based Manufacturing Processes

Additive Joining Subtractive

SLA LENS

SLS LOM SLM

 10
Additive Manufacturing Process Categories

LOM

SLA
SLM SLS

LENS

ISO / ASTM 52900:2015

 11
Additive Manufacturing Workflow

3D Model Generation 3D Modelling

of a Part of *.STL file
Verifying Part Orientation
and repairing Data Preparation

Generation of
the slice file
Layer Manufacturing Fabrication Process
Machine
Post-Processing
Post-Process Finishing

Physical Parts Physical Object

 12

Direct Manufacturing of Parts

 Stereolithography (SLA) 13

Stereolithography (SLA or SL) – patented in 1986 as a method/apparatus for

making solid objects in a vat of liquid photopolymer using ultraviolet curable
material and a laser to trace the digital design
Disadvantages:
q models require support structures for
overhanging sections
q requires post-curing
q material stability and properties
Advantages:
q not a thermal process
q the machine runs unattended
q parts can have very good details
q Consistent accuracy (<+/- 0.1 mm)
q Good surface finish comparable to M. F. Ashby, 2011
many machining operations
 SLA: Key Component Technologies 14

Adjustable mirrors
(optional)
Beam Expander
Laser
(optional)

Flat Field Scanning

X-Y Scan Head
Lens

Laser Solid-state f. tripled Nd: YVO₄

Wavelength 354.7 nm
Power (CW mode) 1450 mW
Build Envelop (Vats with Layer thickness 0.05 - 0.15 mm
liquid photopolymer) Border spot (Ø @ 1/e2) Nominal 0.13 mm
Large hatching spot Nominal 0.76 mm
Recoating System
Speed (border) 3.5 m/sec
Z positioning stage Speed (hatching) 25 m/sec
3D Laser Lithography / Direct Laser Writing (NanoScribe) 15

Two-Photon
Stereolithography

Multifocal Multiphoton
Lithography

Two-photon absorption, Wikipedia

 3D Laser Lithography : Key Components 16

Adjustable mirrors
(optional)
Beam Expander
Laser
(optional)

Focusing Lens
(inverted microscope)

Laser Ti-Si laser source

Build Envelop (coated Wavelength 740 nm
substrate with resist, Power 10W
e.g. SU-8)
Voxel size sub-micron
Piezoelectric XYZ Writing field 100 x 100 mm
positional stages
 Selective Laser Sintering (SLSTM) -3D Systems 17

Disadvantages: Advantages:
• relatively long heating up • good accuracy in X,Y directions
and cooling down times • parts nesting within the build
• thermal distortion
• relatively fast for thin-walled or hollow parts
• less accurate in Z direction
• a good variety of materials available
• the powder degrades
 Laser Sintering (LS) - EOS GmbH 18

EOSINT P800
q Max Part Size - 700mm x 380 mm x 600 mm
q 2 Lasers work simultaneously
q Automatic supply of the plastic powder
q Materials: Polyamide, GF Polyamide, Higher temperature polymers (385o C)
 SLS: Key Component Technologies 19

Adjustable mirrors
(optional)

Laser

Flat Field Scanning

X-Y Scan Head
Lens

Laser (polymers) CO2

Wavelength 10.6 μm
Power (CW mode 30-200W
Build Envelop (powder Layer thickness 0.08 – 0.15 mm
bed) Speed (outlining) 5 m/sec
Speed (hatching) 12.7 m/sec
Powder delivery (roller)
Polyamide, GF Polyamide,
Z positioning stage Materials PS, rubber like plastics
 Selective Laser Melting (Powder Bed) 20

CONCEPT M2 CUSING system

q Laser system: NIR fibre laser 200W (cw)
q Build envelope: 250 x 250 x 280 mm
q Layer thickness: 20 - 50 µm
q Production
q speed 2 – 20 cm3/h
q Max. scanning speed 7 m/s
q Focus diameter: 70 – 200 µm
q Semi-automatical powder recycle system
q Materials: Ni, Ti, Al and steels
q Part density: >98%.

Product CAD model

 SLM: Key Component Technologies 21

1, 2 or 4 laser sources with multiple Adjustable mirrors

beam delivery sub-systems (optional)

Laser

Flat Field Scanning

X-Y Scan Head
Lens

Laser (polymers) Yb-doped ns fiber laser

Wavelength 1.064 μm
Power (CW mode) 200-700W
Build Envelop (powder Layer thickness 0.08 – 0.15 mm
bed) Speed (outlining) 5 m/sec
Powder delivery (roller) Speed (hatching) 12.7 m/sec
Materials Ni, Ti, Al and steels
Z positioning stage
Laminated Object Manufacturing (LOM) 22

Scanning Mirror

Hot Roller

Current Prototype
Cross Section

Waste of
Material
Movable
Platform
Supply of
Material
 Laser Engineering Net Shaping (LENSTM) 23

Glove Box
Trumpf 6.5 Axis DLF system
Z (750m m)
Y(1.5 m)
Z-axis
X (3 m) C
q Laser system Nd-YAG laser
B
500W-4kW (cw modulated)
q Glove box size 1.5x1.0x3.0m
KA
A
q Laser spot size: 0.2-6mm
q 6.5-axis CNC control
Small Enclosure
movement
q Materials:¨Ti alloys and Steels

Co-axial Nozzle 3-Beam Nozzle

q used for narrow q Used for thick wall
wall builds builds
q powder Focus ≥ q Powder Focus ≥
0.3 mm 1.5mm
 LENS: Key Components 24

Multi-Axes
Collimator Laser
Robotic Hand

Head with: Laser Nd-YAG laser

• Focusing lens Wavelength 1064 nm
• Powder delivery nozzle(s) Power (CW mode) 500W - 10KW
Layer thickness 0.2 – 2 mm
Laser spot size 0.2-6 mm
Speed 1-10 mm/sec
Workpiece Ti alloys
Swivel rotary (A and C Ni Alloys
axes) table
Materials Steels
 Hybrid Manufacturing Processes: New Trend 25

Additive
Milling, Drilling, …
Manufacturing
Scallan, P. (2003) Process Planning - The Design/Manufacture Interface
Integrex I AM SERIES (MAZAK) 26

The integration of 3D
additive manufacturing
(3D printer) and multi-
tasking machine
INTEGREX series
Integrex i AM SERIES (MAZAK) 27

The cladding heads are

stored in the tool
magazine and loaded on
the turret by the automatic
tool changer. The cladding
heads are selected
according to the type of
process to be performed
and the type of metal
powder to be utilized.
 28

AM Material Issues
 29
AM processes and related polymer materials
Selection of materials for AM metal processes 30
 31
Main Material's Issues
q Limited range of materials available

q Anisotropic properties of parts produced by layer-based

laser processing
§ part orientation determines the properties in different
directions
§ inconsistent “joining” of adjacent layers
§ different laser-material interaction effects
 32

Process Optimisation Issues

 33
Basic Principles of Laser-Based Additive Manufacturing
q 3D model generated (AutoCAD, SolidWorks, etc..)
q Sliced
q Each slice is manufactured and the layers are fused together
q A voxel (volumetric pixel) - a volume element, representing a volume
into a regular grid in 3D space. This is analogous to a pixel, which
represents 2D image data in a bitmap (which is sometimes referred to as
a pixmap).
 Factors Influencing Accuracy (Input Factors) 34

STL files generated by applying Chord

q Errors due to Tessellation Heights of 0.5 mm (left) and 0.05 mm (right)
Chord Height

Part
surface
Tessellated surface

q Errors due to Slicing

Slicing of a ball (A: No slicing, B: Thick slicing, C: Thin

slicing, D: Adaptive slicing)
 Factors Influencing Accuracy (Fabrication) 35

q Process Calibration Errors

Calibration Part

1.5
E
r 1
Error versus nominal r
o 0.5
dimension for the test r
(mm) 0
part along the X and Y
-0.5
axes
-1
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

Nominal dimension (mm)

External along X External along Y
Internal along X Internal along Y
 36
Factors Influencing Accuracy

q Part Build Errors

Shrinkage and laser beam sintering diameter (a - without

compensation, b - after shrinkage and offset compensation)

q Finishing Errors
 Selection of Part Build Orientation 37

Direction 1: 52min, 32 mm2 Direction 1: 75min, 37 mm2

Direction 2: 52min, 32 mm2 Direction 2: 75min, 33 mm2
Direction 3: 72min, 25 mm2 Direction 3: 79min, 39 mm2

Direction 1: 22hr 36min, 6000 mm2

Direction 2: 24hr 42min, 6803 mm2
Direction 3: 24hr 42min, 6803 mm2
Direction 4: 22hr 48min, 8052 mm2
Direction 5: 27hr 57min, 2930 mm2
Orientation Constraints (SLS process) 38

To maximise strength, snaps and pegs

should be built in the X-Y plane

X
Orientation Constraints (SLS process) 39

Fine features should be built facing upward

to achieve better feature definition

X
Current Status 40

q Additive manufacturing processes are not

perfect

q Accuracy, surface finish and resolution can be

improved and existing technologies optimised

q The right selection of the additive

manufacturing process, the process parameters
and part orientation are very important in order
to meet the parts technical requirements
 41
Application of RP

q Functional Parts
q Patterns for Investment and Vacuum Casting
q Medical Models
q Art Models
q Engineering Analysis Models
q Space exploration
q Rapid Tooling
 Functional Parts 42

Assembly /
Functional tests

Patterns for investment casting

 Functional Parts 43

Dentistry (Cynovad, Canada)

crowns, bridges, dental
restorations

Hearing Aids (Siemens Hearing, USA)

custom made to fit in the ear canal
 Functional Parts 44

Laser fabrication (blown

powder)
q Part repair
q Functional parts in Ti64,
IN718, Ti5553

Laser fabrication
(powder bed)
q Ni parts
q Ti parts
q Al parts
 45
Medical Models

The SLA model together with

the template and the implant

Medical model (using

Stereocol resin)
 46
Engineering Analysis Models

Visualisation of Flow Patterns Photoelastic Stress Analysis

Assembly of the cross-flow water The frozen stress

jacket of a V6 high-performance distribution (turbine rotor
racing car engine model of an jet engine)
 47
Art Models
3D model of a water splash and the SLS model

3D shaded image and a cross-section of the cyber sculpture

 Economic Feasibility Study 48

Break-even points for Lever

Component Cost

Lever Temp (3.6 grams)

Volume
 Challenges and Open R&D Issues 49

q Design: New CAD systems are required to design objects

with different materials or microstructure throughout;

q Machine performance: New RP machines have to be

designed for high volume manufacturing; surface finish
and part accuracy should be improved;

q Machine Cost: the high purchase cost vs productivity;

the maintenance cost is higher compared to conventional
machines;

q Materials: very high cost due to the small quantity used;

limited variety of materials and colours.
 50
Conclusions
The main benefits of utilizing Additive Manufacturing

q Engineering:
– more time is available to make and test prototypes;
– more time can be spent on exploring alternative designs;
– design can be finalized much later in the process.
q Manufacturing:
– direct production of prototype injection moulds;
– masters and patterns for a broad range of processes.
q Marketing:
– physical prototypes for tenders;
– customer feedback on design concepts.
 Conclusions 51

q AM together with 3D CAD modeling are essential

part of Concurrent Engineering process

q Many different AM technologies are available now -

but the right selection of particular AM is the key for
the final success
 52
Recommended Reads…

q Further reading in Metal Additive Manufacturing

Additive Manufacturing of Metals :

From Fundamental Technology to
Rocket Nozzles, Medical Implants,
and Custom Jewellery
Author: John O. Milewski
Published by Springer, 234pp, 2017
 53
Recommended Reads…
q Further reading in Additive Manufacturing

3D Printing: Understanding Additive

Manufacturing
Authors: Andreas Gebhardt, Julia
Kessler, Laura Thurn
Published by arl Hanser Verlag
GmbH & Company KG, 2018, 220pp
 Joint MTC-UoB PhD Scholarship on Polygon scanner based USP laser
processing of wafers like LiNi and PCD

Funding: £28,658 per annum (TAX free stipend) and tuition fee for 3.5 years
Supervisors: Prof. S. Dimov (UoB) and Dr S. Marimuthu (MTC)
Eligibility: only UK nationals can apply
Start Date: ASAP but not later than Oct 2024
This PhD project will investigate the fundamental characteristic of polygon scanners
(scanning speed of ~300 m/s) and the use of high-power ultrashort pulsed (USP)
lasers, e.g. 200 W picosecond lasers, for machining advanced wafers with
applications in semiconductor and medical technology industries, especially for
producing sensors and lab-on-the chip devices. It’s expected that polygon scanners
will enable exploitation of high-power USP lasers to their full potential, in both
productivity and quality.
The PhD project is expected to involve and be relevant to some MTC member
companies, e.g. ADVANCETE, IPG, GF+, Rolls-Royce and BAE Systems. In addition,
the PhD project will benefit from the capital investment at the UoB in a multi-axis laser
micro processing system as part of the ESIF SmartFub project.

Further information is available on jobs.ac.uk