Additive manufacturing

What is additive manufacturing?

• Additive manufacturing is a broad term that
indicates a process that builds up material
layers to create an object or part. Traditional
manufacturing techniques mostly remove
material from a larger block in order to create
the desired part.
 Different types of additive manufacturing

• Stereo lithography(SLA)
• Fused deposition modelling (FDM)
• Selective Laser Sintering (SLS)
• Selective Laser Melting (SLM)
• Electron Beam Melting (EBM)
• Laminated object manufacturing (LOM)
 Stereolithography Apparatus(SLA)
• This type of additive manufacturing takes advantage of Photo polymerization. Certain
resins form solid polymers when they are exposed to certain wavelengths of light.
• Systems usually have a vat of photo resins and an elevator.
• The elevator is submerged in the resins so that only a thin layer of resin covers the
elevator.
• The thin layer above the elevator is then exposed to UV light. The material hardens into
the required pattern of the first layer.
• The elevator moves downward and the resin creates a new layer above the hardened
layer. A resin spreader ensures that the layer is continuous and flat. This process is
repeated until the part is formed.
• The part is then removed and unnecessary supports are removed. The part is then fully
cured under UV lamps.
• An alternative SLA process builds from the bottom of the vat, moving the part upward.
This type of Printing requires far less resin to be present in the basin.
• SLA often uses DLP(Digital light processing) projectors as a light source. The DIY
community has begun to co opt digital projectors with their UV blocker removed as a
light source.
 SLA resins
• SLA resins typically are made of a mixture of
monomers, oligomers, photo initiators and UV
blockers.
• When light hits the photoinitiator it breaks into
groups that cause the oligomers and monomers
to cross link to form solid polymers.
• The UV blocker ensures that the UV shone onto
the resin does not penetrate too far into the vat.
This adds the accuracy of the print.
 Fused deposition modelling (FDM)
• FDM works on an "additive" principle by laying down material in layers; a
plastic filament or metal wire is unwound from a coil, is melted in the
extruder and supplies material to produce a part.
• A worm drive usually feeds the filament into the extruder nozzle at a set rate.
• On some machines the nozzle can move in X, Y and Z directions, while on
others the nozzle moves in only the X and y directions and the base moves in
the Z direction.
• Multiple types of plastics can be 3D printed using this technique including
ABS, PLA, PET and nylon.
• FDM machines often have dual nozzles, either for printing multiple colours or
support material. A common support material used is PVA(water soluble).
• Metals with low melting points can be 3D printed using this technique
• This type of 3D printer is by far the most
common and cheapest to purchase.
• It however does not produce brilliant
resolutions, and post printing machining and
treatments are often required.
 Improving surface finish with Acetone
• Due to the poor surface finish produced by FDM 3D
printing, Chemical treatments have been developed.
• Acetone vapour has been found to melt the outermost
layer of 3D printed items creating a smooth surface finish.
• A beaker of acetone is placed in a bell jar along with the
printed part.
• Once the part has a visibly smooth exterior the part must
be removed.
• If the part is left too long in contact with the acetone
vapour it will melt and lose structural rigidity.
 Selective Laser Sintering (SLS)
• SLS is an additive manufacturing technique that uses lasers to bond powder particles
together by heating them to sintering temperatures.
• Generally the machines have a base that moves in the Z direction and a laser that moves
in the X and Y directions.
• The base is heated so that the energy required by the laser is minimised. High energy
lasers are prohibitively expensive, so this reduces the cost of the device substantially.
• A layer of powder is spread across the entirety of the base and the laser sinters only the
parts of the powder layer that form part of the final part. After the first layer has been
sintered, another layer of powder is spread across the base and the next layer is sintered.
In this way 3D models are produced.
• The advantage of this type of additive manufacturing is that there is no need for support
structures to be printed due to the fact that the un-sintered powder acts as the support.
• The disadvantages of this process is that it is energy intensive and produces porous
structures. It also cannot produce fully enclosed hollows due to the fact that the un-
sintered powder will be trapped inside it.
 Selective laser melting (SLM)
• SLM is an additive manufacturing technique that uses lasers to bond powder particles
together by heating them to melting temperatures.
• Generally the machines have a base that moves in the Z direction and a laser that moves in
the X and Y directions.
• The base is heated so that the energy required by the laser is less in order to melt the
powder particles.
• A layer of powder is spread across the entirety of the base and the laser melts only the
parts of the powder layer that form part of the final part. After the first layer has been
melted, another layer of powder is spread across the base and the next layer is melted. In
this way 3D models are produced.
• The advantage of this type of additive manufacturing is that there is no need for support
structures to be printed due to the fact that the un-melted powder acts as the support.
• The disadvantages of this process is that it is energy intensive. It also cannot produce fully
enclosed hollows due to the fact that the un melted powder will be trapped inside it.
• The print volume is sealed off from the atmosphere and filled with an inert gas. This gas
serves to protect the melted powders from oxidation.
 Electron Beam Melting (EBM)
• EBM is an additive manufacturing technique that uses electron beams to bond powder particles
together by heating them to melting temperatures.
• Generally the machines have a base that moves in the Z direction and a laser that moves in the X and Y
directions.
• The base is heated so that the energy required by the laser is less in order to melt the powder particles.
• A layer of powder is spread across the entirety of the base and the electron beam melts only the parts
of the powder layer that form part of the final part. After the first layer has been melted, another layer
of powder is spread across the base and the next layer is melted. In this way 3D models are produced.
• The advantage of this type of additive manufacturing is that there is no need for support structures to
be printed due to the fact that the un-melted powder acts as the support.
• The disadvantages of this process is that it is energy intensive. It also cannot produce fully enclosed
hollows due to the fact that the un-melted powder will be trapped inside it.
• The print volume is sealed off from the atmosphere and is kept at high vacuum. The vacuum serves to
protect the melted powders from oxidation and reduce scattering of electrons.
• The technology manufactures parts in standard metals with high density (above 99%) and good
mechanical properties (comparable to traditional production technologies). Compared to laser melting,
EBM produces less thermal stress.
 Laminated object manufacture (LOM)
• This 3D printing technique uses sheets of
material that are added to a base layer and
scribed to shape.
• Areas that are not part of the assembly are
crosshatched to be removed later
• An adhesive keeps the layers together.
• Once the entire part is complete a block of
material will be present and the crosshatched
sections can just be removed.
 Laminated object manufacturing (LOM)

Process is performed as follows:

• Sheet is adhered to a substrate with a heated roller.
• Laser traces desired dimensions of prototype.
• Laser cross hatches non-part area to facilitate waste
removal.
• Platform with completed layer moves down out of the
way.
• Fresh sheet of material is rolled into position.
• Platform downs into new position to receive next layer.
• The process is repeated.
 Design factors that Impact Cost
• Part Mass – Increased material usage increases cost.
• Part Total Surface Area – High surface area parts will
require proportionally more finishing operations.
• Part Cubic Volume – multiple parts are nested on the
bed for each print, the larger the part volume, the
more bed space it consumes. This drives up the cost.
• Unsupported sections of the part - attracts the cost
of supports
 Generative design using AI
• Generative design is a computer aided process whereby
CAD designs are created using genetic algorithms and AI.
• A user would need to input constraints implicit in the
design, and the generative design algorithm will
determine where material should be deposited.
• The designs tend to have a distinctly biological look.
• Generative design and 3D printing are well matched.
Often designs created in this manner cannot be
manufactured using traditional manufacturing
techniques.
 3D scanners
• Many techniques for 3d scanning have been developed,
using many different image capturing techniques. However
all of the techniques fundamentally make use of image
analysis.
• Laser scanning has been used in the past, however it is
expensive.
• Modern 3D scanning makes use of standard photos and
software in order to create models.
• The package 123D catch (Autodesk) is a great tool for
scanning objects in the real world that the user wishes to
create.
 Software
• There are many pieces of software that can be
used to generate 3D models used in 3D
printing.
• The main players are Autodesk and Siemens.
• For the purpose of this class Autocad 2018,
which is an Autodesk product, will be used.
• It is free to download as a student off the
autodesk website.
 Process of generating 3D models
• Open new file
• Create an .ipt 3D model.
• Export the file as a .STL or .OBJ file.
• Transfer the .STL/.OBJ file to the 3D printer
• The Printer will then print the model.
 Additional software
• CURA – Helps generate support structures for
the model in question
• Meshmixer - Helps generate support
structures for the model in question
• Fusion 360 – An autodesk program that can
be used to make 3D models. Useful for
beginners.