Emerging Technologies:

Additive Manufacturing
Dr Nusrat Tamanna & Dr Kyriaki Corinna Datsiou
Email: N.Tamanna@[email protected]
Contents

• Introduction

• What is AM?
• How does it work?
• AM applications
• Advantages &
Disadvantages

• Methods

• Applications

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Introduction

3
 AM is a controlled process of creating a 3D object by
What is Additive
depositing material in layers, in precise geometric
Manufacturing (AM)?
patterns based on a CAD (Computer Aided Design) model.
2D printing vs 3D printing

5
Overview
AM: How does it work?

6
STL files
An *.STL (STereoLithography) file contains geometrical information about your 3D models. STL
files are widely used in AM and encode the raw surface of a model using small triangles.

Tessellation is the process of tiling a surface

↑ No of triangles ↑ Resolution
with geometric shapes, (e.g. triangles) so that
there are no gaps or overlapping elements.

12 triangles for cube tessellation

STL files contain: https://www.sculpteo.com/en/3d-learning-hub/create-3d-file/what-is-an-stl-file/

• The Vertex coordinates
• The components of the unit Head tessellation with varying facet (triangle) size.
normal vector to the triangle.

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Overview
AM: How does it work?

8
Overview
AM: How does it work?

9
 Textiles AM Applications
Overview

Aerospace

Education Architecture

Construction
Automotive

Tooling

Electronics 10 Healthcare
 Overview Industries - Aerospace applications

A 3D-printed injector head for Ariane 6

launcher [© EOS]

GE9X engine for Boeing 777X containing 300 AM parts (© Boeing).

Titanium AM bracket installed on Airbus

A350XWB (© Airbus) 11
Overview Industries -
Healthcare applications

EXO prosthetic, titanium leg (© EXO) Drug Personalisation

Mandibular plate. Photo via Xilloc 12

Advantages

Geometric freedom

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Advantages
Overview

Material Waste Reduction

https://www.researchgate.net/publication/344612401_Additive_Manufacturing_of_P
iezoelectric_Materials/figures?lo=1&utm_source=google&utm_medium=organic

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 Titanium – AM buckle
Advantages
Overview

Reduction of raw material usage

Conventional Steel buckle

Weight of 155gr ©.SAVING project,

Crucible Industrial Design

Weight of 70gr
✓ Material saving of 55% (85gr)
✓ For an Airbus 380 (853 seats) this would result in 72.5kg overall weight reduction
✓ Leading to a potential 3.3 million litre saving of fuel for the airplane’s lifetime (saving of 1 kg can
save 45,000 litres of fuel over the life of a large passenger plane) whilst equipping an A380 with
AM buckles would cost £165,000.
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Overview
Advantages and Disadvantages

✓ Ability to achieve complex geometries

✓ Customised, tailored components

✓ Minimizes material waste

✓ Reduction of raw material usage

✓ Lightweight components

✓ Excellent for prototyping

✓ Reduces tooling requirements

✓ Increases manufacturing speed for low volumes

- High cost of AM equipment
✓ Reduces energy and environmental impact
- Low manufacturing speed for mass production

- Size limitations for large scale manufacturing

- Lack of industry standards

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Methods

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AM Methods

Vat polymerization Material Jetting /

Extrusion / Fused
/ Stereolithography Direct inkjet printing
deposition modelling

Binder jetting / Powder bed Directed energy

3D printing fusion deposition
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 UV light source
Overview
1. Vat polymerization or Stereolithography

SLA uses a container filled with a photopolymer resin. UV light

is selectively projected on the resin, causing chemical
monomers and oligomers to cross-link together and form
polymers. This process cures and hardens the resin in layers
until the 3D part is complete.

Materials: Photo-curable
resin Platform
• Resins (PP, ABS, PC)
• Resins containing metal, ceramic or glass nanoparticles

✓ High building speed

✓ High dimensional accuracy
✓ Smooth surface finish
✓ Widely available
- Relatively brittle
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Overview
1. Vat polymerization or Stereolithography

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 Filament
Overview Heated
2. Material Extrusion – nozzle

Fused Deposition Modelling

A thermoplastic filament is partially melted and

extruded from a moving deposition head onto a static
worktable at elevated temperature to build parts
layer by layer. Platform

FDM materials:
• Thermoplastic polymers (ABS or PLA)

✓ Inexpensive
Extrusion can be also used for: ✓ Multi-material printing
• “Green” slurries containing ceramic or - Low resolution
metal powders with polymeric binders - Poor surface finish
• Glass
FDM printed part
• Concrete

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Overview
2. Material Extrusion – Fused Deposition Modelling

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Overview
3. Material Jetting or Direct Inkjet Printing
Droplets of build material are selectively deposited through a
nozzle to directly shape 3D parts onto a substrate. Upon
contact, the droplets undergo a phase change under UV light,
creating a solid part.

Materials
Plastics and Polymers (ABS, PLA, PP, PS, PMMA, PC, Nylon)

✓ High accuracy and surface finish

✓ Multi-material printing
✓ Multi-colour printing
- Poor mechanical properties
- Limited materials

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Overview
3. Material Jetting or Direct Inkjet Printing

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 Roller
4. Binder Jetting or 3D Printing
Overview Powder bed

Droplets of liquid polymeric binder are selectively deposited on

a powder bed. The droplets join the powder particles in each
layer to form the desired structure. The box is heated to “set”
the binder and the part can be removed. Parts are considered
“green” (not suitable for end-use) and need to be post- Platform
processed (e.g. sintering, infiltration) to remove binder content
and achieve desirable properties. Binder
droplets

✓ Performed at room temperature

✓ Large build volume (2200×1200×600mm)
- Increased porosity
- Post processing required
- Low dimensional accuracy due to sintering

Materials: Metals: stainless steel, Inconel, metal matrix composites (stainless steel and bronze), Ceramics, Sand
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Overview
4. Binder Jetting or 3D Printing

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 Laser Scanner
Overview
5. Laser powder bed fusion
Laser beam
Roller Powder bed
The system uses a laser to selectively melt powder
particles in layers of controlled thickness. A new layer of
Powder supply
powder is spread across the previous layer by a roller.
Further layers are fused and added. The process repeats
Heated
until the entire model is created. stage

Materials
• Metals (Stainless Steel, Titanium,
Aluminium, Cobalt Chrome, Steel)
• Ceramics
• Glass
• Polymers: nylon

✓ High accuracy High mechanical performance Low porosity

✓ Functionally graded parts possible - Supports required - Expensive equipment
- Laser scan strategies needed to reduce residual stress
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Overview
5. Powder bed fusion

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Overview
6. Directed energy deposition

DED uses a heat source to melt a powder or wire as it is deposited

onto the surface of an object. The material is added layer-by-layer,
fusing material together and solidifies to form an object.

✓ Large scale parts

Materials
✓ Useful for repair
• Metals
✓ Multi-material composition
• Polymers
- Energy intensive
• Ceramics & Glass
- Lower resolution to LPBF
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Overview
6. Directed energy deposition

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Overview
Summary

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Applications in
large construction
MX3D Bridge – Amsterdam (2021)

Designer: Joris Laarman Lab / Strucural Engineer: Arup

4,500kg stainless steel
Robotic 3D construction with wire arc AM
Span 12.5m
Manufactured off site by 4 robots over a 6 month period

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AM Pavilion – Nashville (2018)

Designer: SHoP Architects, Engineers: Thornton Tomasetti

Construction: Branch Technology

Robotic arm-extrusion using carbon fibre reinforced ABS

40 parts printed in 10 weeks
Assembled in 4 days
6.1m height and 12.8m wide
Coated with UV resistant copper paint 34
Structural Nodes for the tensegrity structure in The Hague (2015)

Research Study: Arup

1200 different node designs required to connect cables to struts

Each node requires 6 or 7 plates welded on a central tube

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 All nodes fulfil the same
functionally and structural
performance requirements

20kg 14kg 5kg

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Traditional node AM node
3d printed house –Beckum, Germany (2021)
Architect: Mense Korte / Construction: PERI

Concrete extrusion (aka contour crafting) Manufacturing speed:1m2 double skin wall < 5min
Manufactured on site in 100 hours of printing over 10 months 38
The Dubai Municipality – Dubai (2019)

Designer: Yves Behar / Construction: Apis Cor Contour crafting (9.5m height, 640m2) 39
3D printed bridge – Netherlands (2021)

Construction: BAM and Saint Gobain

Weber Beamix

Contour crafting

Manufactured off site in multiple 3d

printed parts for each of the 5 spans

Length: 29.5m
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3D printed bridge – Netherlands (2021)

Each is simply-supported to 6.5 m,

resulting in a configuration of multiple
statically determinate girders.

Multiple elements are joined together

with prestressing tendons.

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Thank you

Questions