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ADDITIVE MANUFACTURING
(20IP653) L
Module-1
Introduction J
Course Instructor
Vijay Praveen P M
Assistant Professor I
Department of I&P Engg.
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SYLLABUS
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Introduction: Introduction to Prototyping, Traditional
Prototyping Vs. Rapid Prototyping (RP), and
classification of Rapid Manufacturing Processes:J
Additive, Subtractive, Formative, Generic RP process.
Overview of additive manufacturing– History – Need-I
Classification -Additive Manufacturing Technology in
product development-Materials for AdditiveT
Manufacturing Technology – Tooling – Applications

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 Types of Industrial Design Prototyping R

• Iterative Prototyping
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• Parallel Prototyping
• Rapid Prototyping J
• Iterative Prototyping
• Iterative prototyping involves creating a prototype I
from the product design, testing it for usability and
functionality, and then revising what didn’t work.
After testing has concluded, the research team will T
design a new iteration and manufacture it for
testing.
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• Parallel Prototyping
• On the other hand, parallel prototyping is a concept-based L
method where several design concepts are compared
concurrently. Multiple designs are drafted and then
compared to find the best versions before a physical J
prototype is manufactured.
• Rapid Prototyping (High fedlity protoype)
• Rapid prototyping is a more recent product design testing
method that incorporates some aspects of the iterative
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process. This method is fast and accessible for product
designers who can access CAD software and 3D printing
technology in-house. Rapid prototyping utilizes innovative T
technologies—CAD software and 3D printing—to create
seamless data transfer from computer to printer
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 Roles of the Prototypes R

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(1) Experimentation and learning
(2) Testing and proofing J
(3) Communication and interaction
(4) Synthesis and integration I
(5) Scheduling and markers
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(1) Experimentation and learning

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To the product development team, prototypes can be used J

to help the thinking, planning, experimenting and learning
processes while designing the product. Questions and
doubts regarding certain issues of the design can be
addressed by building and studying the prototype I
For example, in designing the appropriate elbow-support
of an office chair, several physical prototypes of such
elbow supports can be built to learn about the “feel” of T
the elbow support when performing typical tasks on the
office chair
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(2) Testing and proofing
Prototypes can also be used for testing and
proofing of ideas and concepts relating to the
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development of the product. For example, in
the early design of folding reading glasses for I
the elderly, concepts and ideas of folding
mechanism can be tested by building rough T
physical prototypes to test and prove these
ideas to see if they work as intended
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(3) Communication and interaction

The prototype also serves the purpose of communicating information

and demonstrating ideas, not just within the product development
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team, but also to management and client (whether in house or
external). Nothing is clearer for explanation or communication of an
idea than a physical prototype where the intended audience can have I
the full experience of the visual and tactile feel of the product
For example, a physical prototype of a cellular phone can be
presented to carefully selected customers. Customers can handle and T
experiment with the phone and give feedback to the development
team on the features of and interactions with the phone, thus
providing valuable information for the team to improve its design
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(4) Synthesis and integration

A prototype can also be used to synthesize the J

entire product concept by bringing the various
components and sub-assemblies together to I
ensure that they will work together. This will
greatly help in the integration of the product
and surface any problems that are related to T
putting the product together

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(5) Scheduling and markers
Prototyping also serves to help in the scheduling
of the product development process and is J
usually used as markers for the end or start of
the various phases of the development effort. I
Each prototype usually marks a completion of a
particular development phase, and with proper
planning, the development schedule can be T
enforced
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 Rapid Prototyping (RP) R

• the goal is to preplan a part to make it as simple as possible in order to get it quickly
and cheaply. Therefore, rapid prototyping parts generally cannot be used as final 13
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Rapid prototyping again is subdivided into R
1.solid imaging or concept modeling, and
2. functional prototyping. L

Solid imaging or concept modeling: If a rapid J

prototyping part is made mainly for 3D
visualization, it is called a solid image, a concept I
model, a mock-up, or even a rapid mock-up.

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If a part has a single or some of the functionalities
of the latter product, it can be used to verify this L
aspect of the engineering design. Consequently it
is called a functional prototype J

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HISTORICAL DEVELOPMENT
The development of Rapid Prototyping is closely tied
in with the development of applications of
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computers in the industry.
The declining cost of computers, especially of
personal and mini computers, has changed the way a J
factory works. The increase in the use of computers
has spurred the advancement in many computer-
related areas including Computer-Aided Design I
(CAD), Computer-Aided Manufacturing (CAM) and
Computer Numerical Control (CNC) machine tools. In
particular, the emergence of RP systems could not T
have been possible without the existence of CAD

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 Classification Rapid Manufacturing R
(RM) process/RP
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1.subtractive process, one starts with a single block of solid
material larger than the final size of the desired object and
material is removed until the desired shape is reached. L
Ex: milling, turning, drilling, sawing, grinding
2. Additive process is the exact reverse in that the end
product is much larger than the material when it started. A J
material is manipulated so that successive portions of it
combine to form the desired object.
Ex: Stereolithography and Selective Laser Sintering I
3.formative process is one where mechanical forces or
restricting forms are applied on a material so as to form it into
the desired shape. T
Ex: Bending, forging, electromagnetic forming and plastic
injection molding
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 FUNDAMENTALS OF RAPID PROTOTYPING R
1. A model or component is modeled on a Computer-Aided Design/ Computer-
Aided Manufacturing (CAD/CAM) system. The model which represents the physical
part to be built must be represented as closed surfaces which unambiguously L
define an enclosed volume. This means that the data must specify the inside,
outside and boundary of the model This requirement will become redundant if the
modeling technique used is solid modeling. This is by virtue of the technique used,
as a valid solid model will automatically be an enclosed volume. J
2. The solid or surface model to be built is next converted into a format dubbed
the “STL” (STereoLithography) file format which originates from 3D Systems. The
STL file format approximates the surfaces of the model by polygons. Highly curved I
surfaces must employ many polygons, which means that STL files for curved parts
can be very large. However, there are some rapid prototyping systems which also
accept IGES (Initial Graphics Exchange Specifications) data, provided it is of the
correct “flavor”. T
3. A computer program analyzes a STL file that defines the model to be fabricated
and “slices” the model into cross sections. The cross sections are systematically
recreated through the solidification of either liquids or powders and then 22
combined to form a 3D model.
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 RP WHEEL R

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Definition: Additive Manufacturing (AM) refers to a

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process by which digital 3D design data is used to
build up a component in layers by depositing J
material.
OR
Definition: Additive manufacturing (AM) is an I
additive process of making a three-dimensional
solid object of virtually any shape from a digital
model, where materials are applied in successive T
layers under computer control.

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 AM Evolution (History of AM) R
● In the 60s Herbert Voelcker had thoughts of the possibilities of using
computer aided machine control to run machines that build parts from CAD L
geometry.
● In the 70s he developed the mathematics to describe 3D aspects that
resulted in the first algorithms for solid modeling.
● In the 80s Carl Deckard came up with the idea of layer-based manufacturing. J
In 1986 Charles hull, of ultra violet products, Inc. Patented this technology,
which is now known as stereolithographic. Later on, Charles hull formed 3d
systems, Inc. and commercialized this technology. I
In the years between 1988, when chuck hull's stereolithographic was first made
available for public purchase,
● In 1989, Scott Crump patented the FDM (Fused deposition modeling)
process, forming the Stratasys Company. T
● In 1989 a group from MIT patented the 3D Printing (3DP) process. These
processes from 1989 are heavily used today, with FDM variants currently being
the most successful.
● Sanders developed ink jet technology process in 1994 30

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Clay pot making
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 Need for Additive Manufacturing R
As additive manufacturing evolves, optimizing
designs for the technology is becoming ever-more L
important to unlocking the full potential of the
technology.
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There are mainly 6 reasons why we need to go for
the design for additive manufacturing, they are:
1. Create parts with greater complexity I
2. Minimal material waste
3. Simplified assembly T
4. Material innovation
5. Cost-effective customization
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6. Minimum support structures
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AM v/s CNC L

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 Difference between AM & CNC machining process R
• An important difference between additive manufacturing technology and
CNC machining process is that a prototype or model is. obtained by layer by
layer addition process as opposed to removing material from a 'block'. L

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 Impact of AM R
Since the emergence of these technologies and
companies, the AM industry has been constantly L
expanding, growing, and advancing with much
enthusiasm. With many industries seeing the lucrative
value and abilities of AM, the market has been J
expanding very quickly.
Many new types of RP and AM methods have been
created since these original pioneers first started I
developing the technology. Some new technology has
been novel and some just variations of the past types.
There has also been a lot of development in the
materials that can be used as well as research into T
making their properties optimal for end use.

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 Steps in AM Process R

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• The limitation here in STL is only geometry information is stored in files
while all other information that a cad model can contain is eliminated such
as unit, color, material, etc. which plays a critical role in the functionality of
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the built part and effects finished parts

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• Once a correct STL file is available, a series of steps is required to
transfer the information to start the build. The needed information
varies, depending on the technology but in general, these steps start
with repairing any errors within the STL file such as gaps between
surface triangle facets, inverted normal where the "wrong side" of a
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triangle facet is identified as the interior of the part.
• Series of steps is carried out to correct possible errors in the model
file. I
• These errors can include missing triangles, inverted or double
triangles, transverse triangles, open edges and contours, and shells.
Each type of error can cause issues in the building process or result in
incorrect parts and geometries. T
• Once the errors have been repaired, proper orientation of the 3d
model with respect to the build platform is- decided. Following the
orientation, the geometry, density, geometry of support structures are
decided and generated in 3d model space and assigned to the part 44
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• Machine preparation can roughly be divided into two groups of tasks
such as machine hardware set up and process control. L
• 1) Machine hardware setup: Hardware setup entails cleaning of build
chamber from the previous build, loading of powder material, a
routine check of all critical build settings and process controls such
as gas pressure, flow rate, oxygen sensors, etc. J
• 2) Process control; The tasks in the, process control group
allow an additive manufacturing system
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To accept and process the build files
Start the build
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• Interrupt the build at any given time if desired or required,
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Preparing the machine for finished part extraction,
Unloading of material. T

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• In this step slicer program is used to divide the models into layers in
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the build direction based on the desired layer thickness.
• Ideally, the layer thickness would be slightly larger than the mean
diameter of powder to achieve high coupling of laser energy input J
into the absorption, heating, and melting of powder.
• Parameters which determine an amount of energy incident onto the
powder bed per unit time, are energy input, beam power, scan I
speed, and focus move.
• Once the slice information is generated, it is transferred into the
interface program that runs on am systems.
• The interface program serves as the interface between information of
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the build and machine controls that carry out the actual build
process.
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 Post processing techniques R

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 Advantages of AM: R
1. Increased design freedom versus conventional casting and machining
2. Light weight structures, made possible either by the use of lattice
design or by designing parts where material is only where it needs to be, L
without other constraints
3. New functions such as complex internal channels or several parts built
in one J
4. Speed: one can do complex parts within hours, with limited human
resources. The only machine operator is needed for loading the data and
powder material, start the process and finally for the finishing. During the I
manufacturing process no operator is needed.
5. Customization: 3D printing processes allow for mass customization,
personalize products according to individual needs and requirements. T
6. Sustainable / environmentally friendly: It provides environmental
efficiencies in terms of the manufacturing process by utilizing upto 90%
of standard materials, and therefore creating less waste.
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7. No tools needed, unlike other conventional metallurgy processes
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which require molds and metal forming or removal tools
8. Short production cycle time: complex parts can be produced layer L
by layer in a few hours in additive machines. The total cycle time
including post processing usually amounts to a few days or weeks
and it is usually much shorter than conventional metallurgy
processes which often require production cycles of several months. J
The process is recommended for he production of parts in small
series.
9. No storage cost: since 3D printer can print products as and when I
needed, and does not cost more than mass manufacturing, no
expense on storage of goods is required.
10. Increase employment opportunities: Widespread use of 3D T
printing technology will increase the demand for designers and
technicians to operate 3D printers and create blueprints for
products.
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 Limitations R
➢ Production series: the AM processes are generally suitable for unitary
or small series and is not relevant for mass production. But progresses
are made to increase machine productivity and thus the production of
larger series. For small sized parts, series up to 25000 parts/year are L
already possible.
➢ Support material removal: when production volumes are small, the
removal of support material is usually not a big issue. When the J
volumes are high, it becomes an important consideration.
➢ Limitations of raw material: in traditional manufacturing, there are a
wide range of materials wherein an additive manufacturing
technology-can work with only a few. More research is required to
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devise methods to enable 3d printed products to be more durable and
robust.
➢ Good skills are required for application design and to set process T
parameters
➢ Material cost: cost of most materials of additive systems is greater
than that of those used for traditional manufacturing
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.Material properties: a limited choice of materials is

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available: Actually, materials and their properties (e.g.,
tensile property, tensile strength, yield strength, and
fatigue) have not been fully characterized. Also, in terms
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of surface quality, even the best RM processes need
perhaps secondary machining and polishing to reach I
acceptable tolerance and surface finish.
Limitations of size: 3d printing technology is currently
limited by size constraints. Very large objects are still not T
feasible when built using 3d printers.
Cost of printers: The cost of a 3d printer is high
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Classification of AM according to ASTM
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 Additive R
Manufacturing Technology in product development
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• The technology of additive manufacturing/3D
printing is divided in two main application
levels: J
• Rapid prototyping
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• Rapid manufacturing.

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• Rapid prototyping again is subdivided into

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– solid imaging or concept modeling,
– functional prototyping. J
Solid imaging or concept modeling: If a rapid
prototyping part is made mainly for 3D visualization, it is
called a solid image, a concept model, a mock-up, or
even a rapid mock-up. I
If a part has a single or some of the functionalities of the
latter product, it can be used to verify this aspect of the
engineering design. Consequently it is called a T
functional prototype

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Direct Manufacturing
Direct Manufacturing leads to final parts that directly come from the L
AM process.
It is not important that the available materials show exactly the same
physical properties as the materials used within traditional fabrication
processes.
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 Two Types of Rapid Tooling: R
Direct vs. Indirect
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 Additive Manufacturing Materials R

• The main classes of materials used in 3D L

printing today are
– Polymers
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– Metals
– Composites
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– Ceramics
– Sand
– Wax
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• Polymers
• The first 3D printing process to be developed, stereolithography,
is a form of vat polymerization that cures resin to build polymer L
parts. Polymers are still a widely used class of 3D printed
materials today, but have evolved far beyond early, brittle
materials J
• ABS (Acrylonitrile butadiene styrene)
•
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PLA (polylactide), including soft PLA
• PC (polycarbonate)
• Polyamide (Nylon)
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Nylon 12 (Tensile strength 45 Mpa)
• Glass filled nylon (12.48 Mpa)
• Epoxy resin
• Wax
• Photopolymer resins 81

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• Metals
• On the metals side, the most commonly 3D printed materials L
include aluminum, titanium, stainless steel, Inconel and cobalt
chrome.
• Copper has historically been difficult to 3D print with laser-based
systems, but innovations such as blue-light lasers make this
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possible; reflective metals like this may be easier to print using
other methods such as binder jetting. An alloy suitable for one
metal 3D printing method may not be appropriate for all such
methods.
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• Metals for 3D printing are generally provided in wire or powder
formats, but can also be mixed with other materials. Newer
“bound metal deposition” (BMD) systems
apply filament or rods consisting of metal powder embedded in
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polymer to build “green” parts that then achieve their final
dimensions and metal properties through firing in an oven, similar
to metal injection molding (MIM).
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• Composites
Composites that combine different types of materials are also L
gaining ground in 3D printing. The composite might be
created during the 3D printing process, or that process might
begin with a material that already includes an additive. J
Polymers reinforced with chopped carbon and glass fibers are
being used for everything from short-run injection molds to
composite layup tools to end-use parts, offering an option in
between neat plastic and more costly metals. I
Some 3D printers offer the ability to lay continuous fiber
reinforcement simultaneous or interspersed with the 3D
printed form; others utilize sheets of reinforcing material T
fused with layers of polymer. Polymer composites like this can
be made strong enough to be an alternative to metal in some
cases, often with significant weight savings.
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• Ceramics
• Ceramics have low absorption and are difficult to print with laser- J
based systems. However, solutions relying on extrusion, material
jetting and photopolymerization have been developed.
• Sand I
• Even sand can be 3D printed through binder jetting to selectively
“glue” the grains together, a technique that is quickly advancing for
both prototype and production foundry molds as well as vacuum- T
form

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 Important Questions R
1) Define prototype and discuss its types.
2) Define RP and discuss its types. L
3) Define AM .what are the advantages, disadvantages and
its applications.
4) Discuss the Evolution of AM and its classification . J
5) Explain AM Process.
6) What are the postprocessing techniques used in AM and
explain. I
7) What are the difference between Additive and
Subtractive manufacturing,
8) What are the difference between CNC and AM. T
9) Discuss the AM technology used in Product
development.
10) Write a note on materials used in AM. 85

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