Additive Manufacturing

Additive Manufacturing
Dr. P.V.R. Ravindra Reddy

Professor and Head of the Department
Mechanical Engineering
Chaitanya Bharathi Institute of Technology
What are you going study?
• UNIT - V
• Additive Manufacturing: Introduction, Liquid based, powder based
and deposition based layer wise manufacturing, Apllications of
additive manufacturing.
• Powder Processing: Introduction, Production of powders, mixing,
blending, compacting and sintering. Secondary processes such as
repressing, coining, sizing, P/M Forging, Impregnation and infiltration.
Merits, demerits and application of powder metallurgy products
• Processing of Plastics, Ceramics and Composites: Injection moulding,
Blow moulding, Thermoforming, Extrusion, Compression and transfer
moulding processes. Ceramic processing techniques such as injection
moulding and slip casting. Processing methods of composites such as
roll bending, diffusion bonding, Pultrusion and filament winding
processes.
Manufacturing Process – definition
• It is the process of
producing desired
component using
raw material
Basic Manufacturing Processes
• Metal Casting
• Fabrication
• Metal Forming
• Machining
Advanced Manufacturing Processes
• Additive Manufacturing
• Non conventional Machining
processes
• Non Conventional forming Processes
• Powder Processing etc.
Additive Manufacturing
• Additive Manufacturing (AM) refers to a process by which
digital 3D design data is used to build up a component in layers
by depositing material.
• Early use of AM in the form of Rapid Prototyping focused on
preproduction visualizationmodels.
• More recently, AM is being used to fabricate end-use products
in aircraft, dental restorations, medical implants,automobiles,
and even fashion products
Steps Additive manufacturing
• Geometric modelling: Generation of CAD
model
• Tessellation of Geometric model: CAD model is
converted to a format that approximate its
sufaces by triangles. Most used format is STL
format
• Slicing of the model into layers: the model in
STL format is sliced into closely spaced parellal
horizantal layers
Additive manufactuing in orthopedics
Additive manufacturing products
Types of additive manufacturing processes
• Liquid based
• Powder based
• Molten material based
• Solid sheets
Liquid Based processes
• Stereolithography
• Mask Projection Stereolithography
Stereolithography
• It is first additive manufacturing Technology
developed (1988)
• It is the process for fabricating solid part out of photo
sensitive liquid polymer using a directed laser beam
to solidify the polymer.
Stereolithography
• Plat form can be moved vertically inside the vessel
• Laser beam is controlled in x-y direction
• Laser cures the polymer and hardens the layer
• The part is formed by lowering the platform after
each layer and movement of Laser in X-Y plane.
• typical layer thicknesses are from 0.05 to 0.15 mm
• the liquid photopolymers include Epoxy, Acrylic etc.
Mask Projection Stereolithography
• Instead of single scannig laser the entire
layer of liquid photopolymer is exposed at
once to an ultraviolet light source thorugh a
mask.
• Masking is done by digital micro mirror
device (DMD), which contains several
hundred thousands of aluminum mirrors
arranged in rectangular pattern.
• The mirrors which are only about 16 μm
across can be induvidually rotated
between on and off states
corresponding to the bright and dark
pixels in dyanmic mask
• Light from UV source is focus on the
DMD whcih reflects the mask Image
corresponding to the programmed layer
pattern onto the liquid polymer.
Powder based processes
• stating material is powder
• These are also called as Powder bed fusion processes
• Types
– Selective Laser sintering (SLS)
– Three dimensional Printing
Selective Laser Sintering (SLS)
• Roller from the powder
delivery system spreads the
heated powder over the
surface
• Laser beam fuses the powders
in the are corresponding to
the CAD geometric model one
layer at a time.
• Layer thickness ranges from
0.075 to 0.5 mm
• Stereolithography is limited to https://www.youtube.com/watch?
photo polymers where as SLS v=9E5MfBAV_tA
can be used for plymers,
Metals and ceramics
Three Dimesional Printing
• An ink jet printer ejects
the binding material on
successive layers of
powders .
• To further strengthen
the part sintering is
done
https://
www.youtube.com/
watch?v=ONMYx1yhJuo
Molten Material based processes
• Molten material just above the melting point is
deposited in the form of layers.
• the melting requirement limts the materials to be
thermoplastic materials, wax etc.
• Types
– Fused Deposition Modelling (FDM)
– Droplet Deposition Modelling
Fused Deposition Modelling
• The filament of Wax or
thermoplastic polymer is
exruded onto the part of
existing part surface form
the work head to complete
each layer.
• The filament is heated to
about 0.5 deg above the
melting point.
• The work head is
controlled in the x-y plane https://www.youtube.com/watch?
during each layer and then v=J4OQQ9bA6g0
moved up a distance of
one layer in Z direction
Droplet Deposition Manufacturing(DDM)
• It is also known as
ballistic- particle
Manufacturing
• It is based on melting
the material and
shooting the small
droplets onto the
previously formed layer
• the particles are welded
to the previoys layer

Additive Manufacturing

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Additive Manufacturing

Dr. P.V.R. Ravindra Reddy

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