Automation

Defined as the process of following pre determined sequence of

operations with little or no human Intervention using specialized
equipments and devices that performs and controls the manufacturing
Process.
The technology concerned with the application of complex mechanical,
electronics and computer based systems to operate and control
Production System
production.
A collection of people, equipment, and procedures organized to accomplish the
Manufacturing operations of a company
. Automation of the manufacturing system
. Automation of manufacturing support systems
 Automation of the manufacturing system operates in the factory on
the physical product.
 They perform operations such as processing, assembly, inspection or
material handling.
Automated machine tools
Transfer lines performing series of machining operation
Manufacturing systems using robots for processing/assembly.
Automatic material handling and storage
Automatic inspection system for quality control
It is classified into the following three
 Fixed Automation
Sequence of processing (or assembly) operations is fixed by the equipment configuration
Ex: Feeding of rotating spindle
Typical features:
 Suited to high production quantities
 High initial investment for custom-engineered equipment
 High production rates
 Relatively inflexible in accommodating product variety
The economic justification for fixed automation is found in products that are produced in very
Large quantities and at high production rate.
Application: Machining transfer, automated assembly machines.
Programmable Automation
The production equipment is designed with the Capability to change the sequence of
operations through re-programming to accommodate different product configurations. The
operation sequence is controlled by a program, which is a set of instructions coded so that
they can be read and interpreted by the system. It can also be modified or new programs can
be prepared to produce new products.
Typical features:
High investment in programmable equipment
Lower production rates than fixed automation
Flexibility to deal with variations and changes in product configuration
Most suitable for batch production
Physical setup and part program must be changed between jobs (batches)
Ex: NC Machines, Industrial Robots, PLC(Programmable logic controller)
Flexible Automation
Extension of programmable automation.
System is capable of changing over from one job to the next with little lost time between
jobs.
It is a case of soft variety, so that the amount of changeover required between styles is
minimal. Typical features:
High investment for custom-engineered system
Continuous production of variable mixes of products
Medium production rates
Flexibility to deal with product design variations

Programmable
Automation
Variety Flexible
Automation
Fixed
Automation

1 100 10,000 1,000,000

Quantity
 Automation of manufacturing support
systems
Business functions –
sales and marketing, order entry, cost
accounting,
customer billing
Product design - research and development,
design engineering, prototype shop
Manufacturing planning - process planning,
production planning, MRP, capacity planning
Manufacturing control
Automation
shop floorof control,
manufacturing supportcontrol,
inventory systems quality
is control
aimed at reducing the amount of manual
(INFORMATION PROCESSING CYCLE)
and clerical efforts in product design,
manufacturing planning and control, and
business function of the firm.
CIM(Computer Integrated Manufacturing): pervasive use of computer
systems to design the products, plan the production, control the
operation, and perform business function
D: Computer Aided Design: use of computer systems to support product design
M: Computer Aided Manufacturing: use of computer systems to support
manufacturing
= CAD+ CAM+ Business functions related to manufacturing
Reasons for Automating

1. To increase labor productivity

2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually
9. To avoid the high cost of not automating
Numerical Control (NC) refers to the method of controlling the manufacturing operation by
means of directly inserted coded alpha numerical instructions into the machine tool.
It is a form of programmable automation.
A numerical control, or “NC”, system controls many machine functions and movements which
were traditionally performed by skilled machinists.
Numerical control developed out of the need to meet the requirements of high production
rates, uniformity and consistent part quality.
Programmed instructions are converted into output signals which in turn control machine
operations such as spindle speeds, tool selection, tool movement, and cutting fluid flow.
It is easier to write new program than to make major alternation of the processing equipment.
Hence, capability to change the program makes NC suitable for small and medium production.
Machine tool application: Turning, Milling, drilling, boring
Non-Machine tool application: Assembling, Inspection, Material Handling, Drafting, polishing

sic components of “NC”, system

rogram of instructions /part program
Detailed step by step commands that direct the actions of the processing
equipment.
Command may be referred to positioning of cutting tool/machine spindle
w.r.t. work table Or selection of spindle speed, feed rate, cutting tool and
other functions.
The program is coded on a suitable medium like 1 inch wide punched ta
(earlier), Magnetic Tapes, diskettes, and electronic transfer of part prog
from a computer.
2. Machine Control Unit(MCU)
 Consist of electronic and controlled hardware that read and
interpret the program of instructions And convert it into
mechanical action of the machine tools and other processing
equipments.
 Type of readers depend on the storage media for the part
program. Punched tape reader, magnetic Tape reader, floppy
disk drive.
 Includes
Processing control system software, calculation algorithm, and
Equipment
 It performs
translation software
the useful to convert NC part program to suitable
work.
 Its operation
format. is directed by MCU.
 It consist of work table, spindle, motor and controls needed to drive t
 Types of NC systems
1. Traditional numerical control (NC);
2. Computer numerical control (CNC);
3. Distributed numerical control (DNC).
Traditional numerical control machines have “hardwired” control, whereby
control is accomplished through the use of punched paper (or plastic) tapes
or cards. Tapes tend to wear, and become dirty, thus causing misreading.
Many other problems arise from the use of NC tapes, for example the need to
manual reload the NC tapes for each new part and the lack of program
editing abilities, which increases the lead time.

CNC refers to a system that has a local computer to store all required
numerical data. Use of CNC allowed the use of other storage media, magnetic
tapes and hard disks. The advantages of CNC systems are not limited to the
possibility to store and execute a number of large programs (especially if a
three or more dimensional machining of complex shapes is considered), to
allow editing of programs, to execute cycles of machining commands, Etc.
The development of CNC over many years, along with the development of
local area networking, has evolved in the modern concept of DNC.
Distributed numerical control is similar to CNC, except a remote
computer is used to control a number of machines. An off-site mainframe
host computer holds programs for all parts to be produced in the DNC facility.
Programs are downloaded from the mainframe computer, and then the local
controller feeds instructions to the hardwired NC machine. The recent
NC CO ORDINATE SYSTEM
A standard axis system must be defined by which the positioning of the work
head relative to the Work part can be specified.
1. Flat and Prismatic work part: drilling and punching of flat sheet metals to
distinguish +ve from - ve Right Hand Rule is used.
2. Rotational parts: Associated with NC lathes and turning centers. The path
of the cutting tool relative to the rotating work piece is defined in the X-Z
plane where the X axis is the radial location and Z axis is parallel to the
axis of the part.
The part programmer must decide where the origin of the coordinate axis
system
should be Located based on programming convenience. Ex: Corner of the
part or center
(Symmetrical w/p). It is called as “Target point”.
FIXED ZERO VERSUS FLOATING POINT ZERO
NC machines have either of two methods for specifying the zero point. The
first possiblity is for the machines to have fixed zero. In this case the origin is
always located at the same position is for the machine table. Usually that
position is the southwest corner of the table and all the tool locations will be
defined by positive x and y coordinates.
The second and more common feature on modern NC machines allows the
machine operator to set the zero point at any position on the machine table.
This feature is called floating point zero. The part programmer is the one who
decides where the zero point should be located. The decision is based on
Motion control
1. Point-to-point systems:
Some machine tools for example drilling, boring
and tapping machines etc, require the cutter and
the work piece to be placed at a certain fixed
relative positions, without regard for the speed &
path taken to get to that location at which they
must remain while the cutter does its work. These
machines are known as point-to-point machines
2. Continuous path systems
In this system, relative positions of the work piece
and the tool is continuously controlled. It involves
motion of work piece with respect to the cutter
while cutting operation is taking place as in milling,
turning, routing machines etc.
Contouring machines can also be used as point-to-
point machines, but it will be uneconomical.
When tool is moved parallel to only one of the
major axes: Straight cut NC
When simultaneous control of two or more axes is
done in machining operation: Contouring
Absolute and Incremental Positioning:
An absolute NC system is one in which all position coordinates are referred to one fixed origin
called the zero point. The zero point may be defined at any suitable point within the limits of the
machine tool table and can be redefined from time to time. Any particular definition of the zero
point remains valid till another definition is made.
In an incremental system the movements in each Part program block are expressed as the
displacements along each coordinate axes with reference to the final position achieved at the
end of executing the previous program block.

INTERPOLATIONS:
Interpolation consists in the calculation of the coordinated movement of several axes using the
programmed parameters, in order to obtain a resulting trajectory, which can be of various types,
such as: - Straight line, Circular, Helicoidal
The interpolation module computes instant by instant position commands for the servo module,
which in turn, drives the motors. There are two types of interpolators, namely:
- Process interpolator (for continuous axes)
- Point-to-point interpolator (for point-to-point axes)
The various interpolations are:
1. Linear Interpolation
2. Circular Interpolation
3. Helical Interpolation
4. Parabolic and Cubic interpolation.
NC Part Programming
It consists of planning and documenting the sequence of
processing steps to be performed on an NC machine.
Part program: A computer program to specify
- Which tool should be loaded on the machine spindle;
- What are the cutting conditions (speed, feed, coolant ON/OFF etc)
- The start point and end point of a motion segment
- how to move the tool with respect to the machine.
- application of cutting fluids.

A Binary digit is a bit. Represented by presence or absence of hole

Combination of bits Character (0 to 9, A to Z) Combination of

characters
Word Combination of words Block.

A Block is one complete NC instruction.

Manual part programming

Computer assisted part programming
Part programming with APT
Part programming using CAD/CAM
 NC Words (Codes)
N Code - Sequence Number : identifying program blocks
G Code - Control Functions/ Preparatory functions: set up the mode in which
the rest of the operation is to be executed
D Code- Dimension words, specify the coordinate positions of the
programmed path.
X and Z specify the absolute coordinates, and U and W specify the
incremental coordinates
F Code - Feed Rate
S Code - Spindle Speed
T Code - Tool Selection
G Codes M Codes
M Code - Miscellaneous functions
G00 Positioning (not cutting) M00 Program stop
G01 Linear interpolation M02 Program end
G02 Clockwise circular interpolation M03 Start spindle CW
G03 Counterclockwise circular interpolation M04 Start spindle CCW
G20 Inch data input M05 Stop spindle
G21 Metric data input M06 Execute tool change
G54 Workpart coordinate preset M07 Turn coolant on
G80 Canned cycle cancel M25 Open chuck
G81-89 Canned cycles M26 Close chuck
G90 Absolute programming M30 Stop Machine
G91 Incremental programming
 Sequence and format of words:

N3 G2 X+1.4 Y+1.4 Z+1.4 I1.4 J1.4 K1.4 F3.2 S4 T4 M2

sequence no destination coordinates dist to center of circle tool

feed rate spindle speed

preparatory function
miscellaneous function
O0013
N0010 T0404
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0
N0050 X50.0 Z50.0
N0060 T0404
N0070 G57 G00 X25.00 Z2.0 S500 M04
N0080 G01 X22.5 Z-70.0 F100
N0090 G00 X26.0 Z2.0 S500
N0100 G84 X17.5 Z-20.0 D0=200 D2=200
D3=650
N0110 G00 Z2.0
N0120 X50.0 Z50.0 T00
O0013
Program identification number
N0010 T0404
N0010 Sequence number
T0404 Select tool number 404
N0020 G57 G00 X26.0 Z0.0 S500 M04
G57 PS0
G00 Rapid movement (no cutting)
X26.0 X location (as a diameter; 13 form
zero)
Z0.0 Z location
S500 Spindle speed is 500 rpm
M04 Rotate spindle counterclockwise
N0030 G01 X-0.20 F100
G01 Linear interpolation (cutting)
X-0.20 Move only in x direction until you
pass the center by 0.1 mm (facing)
F100 Set feed rate to 100 mm/min.
N0040 G00 Z2.0
G00 Move rapidly away from work piece (no
cutting) Z2.0 the movement is 2 mm away
from the face.
N0070 G57 G00 X25.00 Z2.0 S500 M04
G57 PS0
G00 Rapid movement (no cutting)
X25.0 X location (as a diameter; 12.5 form
zero) Z2.0 Z location
S500 Spindle speed is 500 rpm
M04 Rotate spindle counterclockwise
N0080 G01 X22.5 Z-70.0 F100
G01 Linear interpolation (cutting)
Z-70 Move only in z direction (external
turning)
F100 Set feed rate to 100 mm/min.
N0090 G00 X26.0 Z2.0 S500
G00 Move rapidly away from workpiece (no
cutting) to location x= 26.0 (13.0 from zero)
and z = 2.0.
N0100 G84 X17.5 Z-20.0 D0=200 D2=200 D3=650
G84 Turning cycle for machining the step
X17.5 final diameter Z-20 length of step is 20
mm D0=200 Finish allowance in X direction
(0.2 mm) D2=200 Finish allowance in Z
direction (0.2 mm)
D3=650 Depth of cut in each pass (0.65 mm)
N0110 G00 Z2.0
G00 Move rapidly away from workpiece (no
cutting) Z2.0 the movement is 2 mm away
from the face.
N0120 X50.0 Z50.0 T00
X50.0 Z50.0 Move to the tool changing
location
T00 cancel tool selection
N0130 M30
M30 Program End
PART PROGRAMMING WITH APT

1.Geometric Statement: To define geometry element that comprise

the part
2.Motion statement: To specify the tool path
3.Post processor statement: To specify speeds and feeds, set tolerance
values
4. Auxiliary statement: Miscellaneous statements used to name the
part program, Insert comments
1. SYMBOL=GEOMETRY TYPE/descriptive data POINT
LINE
P1=POINT/20.0,40.0,60.0 PLANE
P2=POINT/INTOF,L1,L2 CIRCLE
L3=LINE/P3,P4
L4=LINE/P5,PARLEL,L3
PL1=PLANE/P1,P2,P3
PL2=PLANE/P4,PARLEL,PL1
C1=CIRCLE/CENTER,P1,RADIUS,25.0
C2=CIRCLE/P4,P5,P6
L1=LINE/P1,LEFT,TANTO,C1

L2 =LINE/P1,RIGHT,TANTO,C1

L3=LINE/P1,ATANGL,20,XAXIS

L4=LINE/P1,ATANGL,30,L3

L5=LINE/P1,PERPTO,L3

L6=LINE/P1,LEFT,TANTO,C1,LEFT,TANTO,C2

L7=LINE/P1,LEFT,TANTO,C1,RIGHT,TANTO,C2

C1 = CIRCLE/CENTER, P1, TANTO, L1

MOTION COMMAND/descriptive data
GOTO/P1 [What move tool should make /Where to go]
At the beginning of the sequence of motion statements, the tool must be
given a starting point likely to be the TARGET POINT, the position
where operator has to position the tool at the start of the job.
FROM/PTARG
FROM/-20.0,-20.0,0
1. POINT TO POINT MOTION COMMANDS
GOTO: Instructs the tool to go to a particular point location
GODLTA: Specifies an incremental move at a particular point
GOTO/P2
GODLTA/0,0,-10.0
GODLTA/0,0,10.0
2. CONTOURING MOTION COMMANDS
Motion of the tool continuously controlled through out the move. The tool is directed
along two intersecting surfaces until it reaches a third surface.
3. Drive Surface: Guides the side of the cutter
4. Part Surface: The bottom of the tool is guided may or may not be actual surface of the part
5. Check Surface: Stops the forward motion of the tool
TO: Positions the leading edge of the tool in contact with the check surface
ON: Positions the centre of the tool on the check surface
PAST: Puts the tool beyond the check surface
TANTO: Tool is tangent to a circular check surface
The programmer must pretend himself on top of the tool as if driving a car for writing
the further motion statement.
GOLFT GORGT GOFWD
GOBACK GOUP GODOWN
To begin the sequence of motion commands FROM statement is used following a GO/TO
statement for defining the initial drive surface, part surface and check surface.
POST PROCESSOR COMMAND/descriptive data
Control the operation of the machine tool and play a supporting role in generating tool path.
Defines cutter size, specify speeds and feeds, turn coolant flow on and off etc.

UNITS/MM INTOL/O.O2 OUTTOL/0.01 CUTTER/20.0

SPINDL/1000,CLW or CCLW SPINDL/OFF FEDRAT/40,IPM or IPR
(units per min or revolution)
RAPID COOLANT/FLOOD LOADTL/01 DELAY/30

AUXILIARY COMMAND
Identify the part program, specify the post processor, insert remark into the program, etc.
PARTNO MACHIN/ REMARK CLPRNT FINI
te the geometry and motion statements for the part given be
drilling:
ndle Speed=1000 rpm and Feed rate=0.05 mm per rev
Milling cutter:
ndle Speed=1000 rpm and Feed rate=50 mm/min
PARTNO DRILLING OPERATION
MACHIN/DRIL,03
CLPRNT
UNITS/MM
REMARK Target point is defined 10 mm above the part surface
PTARG = POINT/0.0,-50.0,10.0
REMARK Geometry statements already written and motion
statement starts
FROM/PTARG
RAPID
GOTO/P5
SPINDL/1000,CLW
FEDRAT/0.05,IPR
GODLTA/0.0,0.0,-15
GODLTA/0.0,0.0,20
RAPID
GOTO/P6
SPINDL/1000,CLW
FEDRAT/0.05,IPR
GODLTA/0.0,0.0,-15
GODLTA/0.0,0.0,20
RAPID
SPINDL/1000,CLW
FEDRAT/0.05,IPR
GODLTA/0.0,0.0,-15
GODLTA/0.0,0.0,20
RAPID
GOTO/PTARG
SPINDL/OFF
FINI

PARTNO MILLING OPERATION

MACHIN/MILLING,02
CLPRNT
UNITS/MM
CUTTER/20.0
PTARG = POINT/0.0,-50.0,10.0
PL1= PLANE/P1,P2,P3
FROM/PTARG
SPINDL/1000,CLW
FEDRAT/50,IPM
GO/TO,L1,TO,PL1,ON,L4
GORGT/L1,PAST,L2
GOLFT/L2,TANTO,C1
GOFWD/C1,PAST,L3
GOFWD/L3,PAST,L4
GOLFT/L4,PAST,L1
RAPID
GOTO/PTARG
SPINDL/OFF
FINI
2.The outline of the part is to be profile milled, using a
20 mm diameter end mill with two teeth. The part is 10
mm thick. Cutting speed = 125 m/min and feed = 0.10
mm/tooth. Use the lower left hand corner of the part as
the origin. Write the APT statement for producing the
part.
ARTNO GEOMETRIC STATEMENT
NITS/MM
1=POINT/0.0,0.0,0.0
2=POINT/75.0,0.0,0.0
3=POINT/150.0,70.0,0.0
4=POINT/50.0,125.0,0.0
5=POINT/0.0,125.0,0.0
6=POINT/25.0,25.0,0.0
7=POINT/25.0,100.0,0.0
8=POINT/80.0,100.0,0.0
1=LINE/P1,P2
2=LINE/P2,ATANGL,35,XAXIS
3=LINE/P3,PERPTO,XAXIS
1=CIRCLE/CENTER,P8,RADIUS,30.0
4=LINE/P3,LEFT,TANTO,C1
5=LINE/P4,RIGHT,TANTO,C1
6=LINE/P4,P5
7=LINE/P5,P1
L1=PLANE/P1,P3,P4
INI
ARTNO DRILLING OPERATION
ACHIN/DRIL,03
LPRNT
NITS/MM
EMARK Target point is defined 10mm above part surface
TARG=POINT/0.0,-50.0,10.0
ROM/PTARG
APID
OTO/P6
PINDL/1000,CLW
EDRAT/0.05,IPR
ODLTA/0.0,0.0,-15
GODLTA/0.0,0.0,20
RAPID
GOTO/P7
GODLTA/0.0,0.0,-15.0
GODLTA/0.0,0.0,20.0
RAPID
GOTO/PTARG
SPINDL/OFF
FINI
PARTNO MILLING OPERATION
MACHIN/MILLING,02
CLPRNT
UNITS/MM
CUTTER/20.0
FROM/PTARG
SPINDL/1990,CLW
REMARK Pitch=πd/2 and speed in rpm=linear
speed/pitch
FEDRAT/0.2,IPR
GO/TO,L1,TO,PL1,ON,L7
GORGT/L1,PAST,L2
GOLFT/L2,PAST,L3
GOLFT/L3,PAST,L4
GOLFT/L4,TANTO,C1
GOFWD/C1,TO,L5
GOFWD/L5,PAST,L6
GOLFT/L6,PAST,L7
GOLFT/L7,PAST,L1
RAPID
GOTO/PTARG
SPINDL/OFF
FINI
3.The outline of the part is to be profile milled, using a 12.5
mm diameter end mill with two teeth. The part is 7.5 mm
thick. Spindle speed = 500 rev/min and feed rate = 0.80
mm/min. Use the lower left hand corner of the part as the
origin. Write the APT statement for producing the part.
YPE OF OPERATION
cording to quantity, there are three types of production
1. Job shop production
2. Batch production
3. Mass production / Continuous production

JOB SHOP
PRODUCTION
Product
Variety
BATCH
PRODUCTION
MASS
PRODUCTION

1 100 10,000 1,000,000

Production Quantity
JOB SHOP PRODUCTION
It is of low volume i.e. manufacturing lot sizes are small and they are of one
kind.
Production equipments are general and flexible for variety of work.
Skill level of workers is high.
Ex: Local industrial machinery, farm machinery, boats and ships, or even batches of
specialized components for the aircraft industry, Space vehicles, Special
machine tools etc.
BATCH PRODUCTION
This category involves manufacturing of medium size lot of same item or
product.
The lot may be produced only once or at regular interval of time.
Ex: industrial equipments, home appliances, text books and clothing
etc.
MASS PRODUCTION(Continuous Production)
It is continuous, specialized manufacturing of identical products.
It is characterized by:
1. Very high production rate
2. Equipments are completely dedicated to manufacturer of a particular
product.
3. Very high demand rates for the product
4. Skill of labour is lower than batch or job shop production.
5. The entire plant is designed for producing a particular product.
It is of two types
1. Quantity production / Mass production
NCTIONS IN MANUFACTURING

cessing and assembling add value to the product but the others don’t.
PROCESSING OPERATION
ansforms the product from one state of completion into some advanced state.
material or component is added or assembled but energy is utilized to change th
pe of the part by removing material from it or by changing physical properties.
ssified as:
1. Basic process
2. Secondary process
3. Operation to enhance physical properties
4. Finishing Operation
SIC PROCESS
raw material are converted into basic geometry of the designed product to give
k material its initial form.
tional processing is required to achieve the final shape and size.
Ex: Metal casting, Moulding

ONDARY PROCESS
llows the basic process and gives the work part its final geometry.
Ex: Machining (Turning, Drilling, Milling etc.)
Press working(Blanking, Forming, Drawing etc)

ERATION TO ENHANCE PHYSICAL PROPERTIES

e, the physical properties of the material are improved but geometrical shape rem
stant.
Ex: Heat treatment operation to strengthen the material

ISHING OPERATION
se are the final processes that are performed on the work part and their purpose
ease appearance, surface finish, surface coating etc.
Ex: Polishing, finishing, chromo painting etc.

SSEMBLING OPERATION
llows the processing operation. Here, two or more separate components are join
ether. Ex: Nut and bolt, Coupling, Riveting, Soldering, Welding, Brazing etc
3. MATERIAL HANDLING AND STORAGE
It is the means of moving and storing material between processing and
assembling Operation.
In most cases material spend more time being moved an stored.
Majority of labour cost in the factory is consumed in handling, moving and
storing material.

4. INSPECTION AND TESTING

These are the functions of Quality control department.

Inspection is done whether the product meets established designed standard
or not.
Testing is concerned with the functional specification of final product.

5. CONTROL

It includes both regulation of individual processing and assembly operation

and the management of the plant level activities.
Control at process level involves achievement of certain processing objective
by proper manipulation of input to the process.
Control at plant level includes effective use of labour, maintenance of
equipment s, moving materials in factory , shipping, good quality products on
schedule & keeping plant operation cost at minimum possible level.
So control is the major intersection between physical operation in the factory
& information processing activities.
 ADDITIVE MANUFACTURING

COMPREHENSIVE OVERVIEW OF
PROCESSES, APPLICATIONS, AND
ROBOTICS INTEGRATION
 Table of
Contents
• 1. Introduction to Additive
Manufacturing
• 2. Generic Additive
Manufacturing Process
• 3. Classification of AM Processes
• 4. Fused Deposition Modeling
(FDM)
• 5. Material Jetting
• 6. Binder Jetting
• 7. Sheet Lamination Process
• 8. Applications of Additive
Manufacturing
• 9. Applications of Robots in
Manufacturing
• 10. Conclusion
Additive Manufacturing:
A Revolution in
Manufacturing
Additive manufacturing, also known as 3D printing, is
revolutionizing the manufacturing industry by
allowing for the creation of complex, customized
products with unparalleled precision. This
presentation explores the fundamentals of additive
manufacturing, its diverse applications, and its
potential to transform the future of production.
 The Generic Additive Manufacturing Proces

Layer-by-Layer Construction Material Deposition

Additive manufacturing builds objects layer by Various additive manufacturing processes utilize
layer, starting with a digital model. A material different methods for material deposition, including
is deposited, solidified, and then the process is powder bed fusion, material extrusion, vat
repeated for each subsequent layer, building a polymerization, and directed energy deposition,
three-dimensional object. each with unique capabilities.
 Classification of Additive
Manufacturing Processes
Material Extrusion Powder Bed Fusion
Material extrusion, also known as fused Powder bed fusion processes use a laser or
deposition modeling (FDM), utilizes a heated electron beam to melt or fuse powdered
nozzle to extrude thermoplastic filament, material, layer by layer, to create a solid object.
creating layer upon layer.

Vat Polymerization Directed Energy Deposition

Vat polymerization processes use a vat of liquid Directed energy deposition processes use a
photopolymer resin, which is selectively cured high-powered laser or electron beam to melt and
using a UV light source, layer by layer. deposit metal powder or wire onto a substrate,
layer by layer.
Fused Deposition Modeling:
Principles and Applications

Principle of Operation
Fused deposition modeling (FDM) employs a thermoplastic filament that is
heated and extruded through a nozzle, forming layers on a build platform,
and creating the desired three-dimensional object.

Common Applications
FDM is widely used in rapid prototyping, custom tooling, and creating
functional prototypes for testing, showcasing its versatility and affordability.

Material Compatibility
FDM is suitable for a variety of thermoplastics, such as ABS, PLA, Nylon, and
PETG, and offers properties like strength, flexibility, and resistance to various
conditions.
 Advantages and Limitations of
Fused Deposition Modeling

Advantages Limitations
• Low Cost • Layer Visibility
• Ease of Use • Limited Material Strength
• Versatile Materials • Surface Finish
• Rapid Prototyping • Support Structures
• High Customization • Size Limitations
Material Jetting: Innovative
Additive Approach
1 Droplet Deposition
Material jetting utilizes a high-precision printhead to deposit
droplets of liquid photopolymer material onto a build platform,
layer by layer, creating intricate details.

2 UV Curing
After each layer of material deposition, a UV light source
selectively cures the photopolymer resin, solidifying the layers
and creating a solid object.

3 Detailed Features
Material jetting offers exceptional resolution and precise
control over droplet placement, enabling the creation of highly
detailed and intricate 3D objects.
 Material Jetting: Materials and Capabilities

Material Selection High Resolution Biomedical Applications

Material jetting uses a wide Material jetting delivers Material jetting offers
range of photopolymer resins, exceptionally high resolution, biocompatible materials,
offering diverse properties like enabling the creation of precise suitable for creating
flexibility, strength, details, complex geometries, and customized medical implants,
transparency, and color intricate features, suitable for surgical guides, and
options, suitable for various jewelry, dental models, and anatomical models,
applications. prototypes. contributing to
advancements in healthcare.
 Introduction to Binder Jetting Process

The Fundamentals How it Works

Binder jetting is an additive manufacturing The binder, typically a liquid or paste, is

process where a binder material is selectively applied to the powder layer through a print
deposited onto a layer of powder material. This head, which moves across the bed and
process is repeated layer by layer to build up selectively binds particles together.
the desired 3D object.
Key Features and Benefits
of Binder Jetting
1 High-Speed 2 Cost-Effectiveness
Production
This process is known for
Binder jetting excels in its low per-part cost,
producing parts at a making it an attractive
significantly faster rate option for high-volume
than other additive production runs.
manufacturing methods.

3 Versatile Material Options

Binder jetting can work with a wide range of powder
materials, including metals, ceramics, and polymers,
allowing for diverse applications.
 Overview of Sheet Lamination Process

Building Layer by Layer A Different Approach

Sheet lamination is an additive manufacturing process This process utilizes a controlled environment
that involves layering thin sheets of material to create and heat to fuse the layers of material
a three-dimensional object. Each sheet is precisely cut together, resulting in a strong and durable
to the desired shape and then laminated together. final product.
Advantages and Applications
of Sheet Lamination
High-Resolution Accuracy Excellent Surface Finish
Sheet lamination is renowned The process generates parts
for its high level of precision and with a smooth and consistent
detailed accuracy in producing surface finish, often eliminating
complex geometric shapes. the need for post-processing.

Wide-Ranging Applications
Sheet lamination finds applications in industries like aerospace,
automotive, medical devices, and consumer products, producing parts
with specific requirements.
The Role of Robots in
Manufacturing
Increased Efficiency
Robots can perform tasks repetitively and accurately, optimizing production
processes and minimizing human error.

Enhanced Productivity
Robotic automation can accelerate production cycles, leading to increased output
and higher production rates.

Improved Safety
By taking over dangerous or repetitive tasks, robots enhance workplace safety
and minimize the risk of accidents.
Robotic Automation in
Additive Manufacturing
Material Handling
Robots can handle materials efficiently, loading and
unloading powders and sheets, and ensuring a smooth
workflow in additive manufacturing.

Process Monitoring
Robots can monitor and adjust printing parameters in real-
time, optimizing the process and ensuring consistent quality.

Post-Processing Tasks
Robotic arms can perform tasks like cleaning, sanding, and
finishing of parts, reducing manual labor and improving
efficiency.
Integrating Additive Manufacturing into Productio
Design Optimization
Additive manufacturing allows for greater design freedom, enabling
1 complex geometries, lightweight designs, and functional integration,
optimizing product performance.

Tooling and Jigs

2 3D printing enables the creation of custom tooling and jigs,
reducing lead times and costs, allowing for faster prototyping
and production processes.

Direct Production
Additive manufacturing can be directly integrated into
3
production lines, eliminating the need for traditional
tooling and enabling the creation of customized and on-
demand products.
 Successful Additive
Manufacturing
1
Implementations
Aerospace
Additive manufacturing is used to create lightweight and durable components for aircraft
and spacecraft, improving efficiency and reducing fuel consumption.

2
Automotive
3D printing is used to create custom parts for vehicles, reducing lead times and allowing
for greater customization, improving vehicle performance.

3
Healthcare

Additive manufacturing is revolutionizing healthcare, enabling the creation of custom

implants, surgical guides, and personalized medical devices.
The Future of Additive Manufacturing: Trends an
Opportunities
Material Innovations
1 New materials with enhanced properties are being developed for additive manufacturing,
enabling the creation of more durable, lightweight, and functional objects.

Automation and Robotics

2 The integration of automation and robotics is increasing the speed and
efficiency of additive manufacturing processes, paving the way for mass
customization.
Industry 4.0 Integration
Additive manufacturing is becoming an
3 integral part of Industry 4.0, with the
emergence of smart factories, connected
machines, and data-driven manufacturing
processes.