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Introduction to Additive Manufacturing

Radha Raman Mishra, Ph. D.

Course Instructor
Assistant Professor of Mechanical Engineering

Concepts of CAD/CAM

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Computer Aided Engineering (CAE)

Automation

CAE CAD CAM

Design formalizes ideas Fabrication of the developed models
through computer modeling into real-world objects

Concepts of Reverse Engineering

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Reverse Engineering (RE)

Physical Geometric Segmentation

Processing of CAD model
Model information
point cloud
and surface
generation CAM
collection fitting

CAD
Scanning

Contact scanning Non-contact scanning

(touch probe) (Optical scanning device)

Manufacturing: Needs of Industries

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Need of AM

Additive Manufacturing (AM)

Process can address such issues

Let us explore the AM process!!

Fig. Three axis model of manufacturing products
#Conner et. al., (2014). Making sense of 3-D printing: Creating a map of AM products and services. Additive Manufacturing, 1, 64-76. 7

Additive Manufacturing
Definition
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.
(from the International Committee F42 for Additive Manufacturing Technologies, ASTM)

Also known as:

• 3D Printing (3DP)
• Rapid Prototyping (RP)
• Direct Digital Manufacturing (DDM)
• Layered manufacturing (LM) and
• Additive fabrication (AF)

However, the AM is more accurate

As it describes a professional production technique which is clearly distinguished from
subtractive manufacturing
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Basic attributes of AM

o Fully automatic operation

o Digital to physical

o No part-specific tooling

Principle of AM
3D Sculpture puzzle: to create the sculpture.

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Principle...

• Layer by layer manufacturing

• Each layer must have a finite thickness

“Thinner each layer is, the closer the final part will be to the original”

CAD image of a teacup Thick layer Thin layer

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Inspiration for AM

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Nature analogy

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Prehistory
Layered Additive Structures have been around for awhile – The oldest pyramid (the Step
Pyramid of King Zoser) was built during the Third Dynasty (ca. 2800 B.C.) at Saqqara .

Fig. The Step Pyramid of King Zoser

https://www.etltravel.com/zoser-pyramids-egypt/zoser-step-pyramid-cairo/ 14

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History (Early patents)

NAME TITLE FILED COUNTRY
Housholder Molding process Dec 1979 U.S.

Murutani Optical molding method May 1984 Japan

Masters Computer automated manufacturing process and system July 1984 U.S.
André et al. Apparatus for making a model of an industrial part July 1984 France
Hull Apparatus for making three-dimensional objects by stereolithography Aug 1984 U.S.
Pomerantz et al. Three-dimensional mapping and modelling apparatus Jun 1986 Israel
Feygin Apparatus and method for forming an integral object from laminations Jun 1986 U.S.
Deckard Method and apparatus for producing parts by selective sintering Oct 1986 U.S.
Method and apparatus for producing three-dimensional objects by photosolidification;
Fudim Feb 1987 U.S.
radiating an uncured photopolymer
Arcella et al. Casting shapes Mar 1987 U.S.
Crump Apparatus and method for creating three-dimensional objects Oct 1989 U.S.
Helinski Method and means for constructing three-dimensional articles by particle deposition Nov 1989 U.S.
Marcus Gas phase selective beam deposition: three dimensional, computer-controlled Dec 1989 U.S.
Sachs et al. Three-dimensional printing Dec 1989 U.S.
Levent et al. Method and apparatus for fabricating three dimensional articles by thermal spray deposition Dec 1990 U.S.
Penn System, method, and process for making three dimensional objects Jun 1992 U.S.
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Selective Laser Sintering by UT

A modern manufacturing technology that was created in the 1980s at The University of Texas at Austin's
Mechanical Engineering Department (UT ME).

From L-R: Carl

Deckard, Joe Beaman,
and Paul Forderhase

Fig. Plastic powder and first SLS part Fig. Early stages of the SLS machine (called Betsy)
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Selective Laser Sintering…

Fig. BAMBI
Machine for SLS

Fig. SLS parts of

plastics developed
using BAMBI
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3D Printer by MIT

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3D Printer by MIT…..

Fig. A 3D printed model

Fig. First 3D printer v1.1 at MIT
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Process characteristics

Differentiation of AM machines Responses in AM Process

• Materials that can be used
Final Product
• Creation of layers • Accuracy
• Material properties and
• Bonding of the layers
• Mechanical properties
• Layer deposition pattern
Process
• Speed
• Post-processing requirements
• Size of the AM machine and
• Overall cost of the machine and
process

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Additive vs Subtractive manufacturing

Property SM AM
Material Metals and alloys All engineering
materials
Speed Multi-stage and Single stage and
slow fast
Part • Limited • More
Complexity flexibility flexibility
• Needs more • Easy to
process manufacture
planning
Part Low Higher
Quantity
Cost High Low

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Additive vs Subtractive manufacturing

Deep cavity: Difficult
to machine

Sharpe internal features:

need a tool radius

Undercut: 3-axis
machining is required

Cup base: can not be machined

(fixture requirement)
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AM Attributes

Fig. Scope of customization in AM*

Fig. Conventional vs Additive manufacturing

Thompson et. al. (2016). Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints. CIRP annals, 65(2), 737-760.
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Social Impact of AM
Energy
Dimension Time
Dimension

Final Product
Processing Material Scrap
Material Time
Dimension Process Waste

These include:
Energy • Customized healthcare products
Wastage • Reduced raw material usage
• Reduced energy consumption
(environmental sustainability)
• On-demand manufacturing
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Advantages
1. Complexity is Free 2. Variety is Free

3. No Assembly Required

4. Zero Lead Time 5. Zero Constraints

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Advantages
6. Zero Skill Manufacturing 7. Compact & Portable Manufacturing

8. Less Waste By-product

10. Precise Replication

9. Infinite Shades of Materials

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Disadvantages
• Limited Materials
• Restricted Build Size
• Post Processing
• Large Volumes
• Part Structure
• Reduction in Manufacturing Jobs
• Design Inaccuracies
• Copyright Issues

https://www.twi-global.com/technical-knowledge/faqs/what-is-3d-printing/pros-and-cons 27

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Applications

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Application (Medical)

A 3D model of a complex anaplastology case

Fig. A titanium acetabular cup produced. Inset shows close up of highly complex surface
Ben Deighton, Rethinking objects and form are key to 3D printing revolution, Techanology News, March 2013.
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Application (Automobile)

(Image: Dane Boysen, Adapted from Koren, Y., et al. CIRP Annals-Manufacturing Technology 62.2 (2013):719–729.) (Image: Business Wire)
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Application (Civil Structures)

Different Civil Structures L&T 3D prints first G+1 building L&T 3D prints Post-office

(Image: https://www.constructionworld.in/latest-construction-technology/l-t-3d-prints-first-g-1-building-in-india/25144)
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AM: Application Levels

Technology: the science of the technical process (Scientific approach)

Application: use of the technology to benefit from it (Practical Approach)

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Main application levels

Gebhardt, Understanding Additive Manufacturing, Hanser Publishers 2011. 33

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Application Levels – Direct Processes

Scaled assembly of a roof construction of a

convertible passenger car

Cut-away demonstrating part of a

combustion engine unit

Gebhardt, Understanding Additive Manufacturing, Hanser Publishers 2011. 34

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Application Levels – Direct Processes

Adjustable air outlet grill for a passenger

car: laser stereolithography

Housing for a re-designed mobile

phone: FDM

Gebhardt, Understanding Additive Manufacturing, Hanser Publishers 2011. 35

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Application Levels – Direct Processes

Three-unit dental bridge: SLM

Aircraft engine cover hinge: SLM (Bottom)

Gebhardt, Understanding Additive Manufacturing, Hanser Publishers 2011. 36

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Application Levels – Direct Processes

Steel mold for blow molding.

Direct metal laser sintering

Gebhardt, Understanding Additive Manufacturing, Hanser Publishers 2011. 37

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Application Levels – Direct Processes

Rubber boot sole mold: laser sintering

Mold insert; stereolithography

Gebhardt, Understanding Additive Manufacturing, Hanser Publishers 2011. 38

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Application Levels – Direct Processes

Gebhardt, Understanding Additive Manufacturing, Hanser Publishers 2011. 39

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Application Levels – Indirect Processes

Lighter “Bruce”; AM master: stereolithography

Triangle-shaped gasket for car mirror fixation

Gebhardt, Understanding Additive Manufacturing, Hanser Publishers 2011. 40

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Application Levels – Indirect Processes

Mold obtained from an AM master

Rigid mold made from aluminum filled epoxy

Stereolithographic

Gebhardt, Understanding Additive Manufacturing, Hanser Publishers 2011. 41

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Application Levels – Indirect Processes

Combustion engine housing; AM master (left): laser

sintering

Air intake manifold: laser sintering

Gebhardt, Understanding Additive Manufacturing, Hanser Publishers 2011. 42

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Gebhardt, Understanding Additive Manufacturing, Hanser Publishers 2011. 43

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AM: Processes and Relevant Physics

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General integration of an AM machine

Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies: rapid prototyping to direct digital manufacturing Springer, 2010. 45

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Classification of AM Processes
• A popular approaches of classification –
• Baseline technology – lasers, printer, extrusion etc.
• Group processes together according to the type of raw material input

• Problems:
 Odd combinations of processes
(like Selective Laser Sintering (SLS) and 3D Printing)

 Similar processes but separated

(like Stereolithography and material jetting with photopolymers).

• Thus, these approaches seems inappropriate to cover all processes

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Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies: rapid prototyping to direct digital manufacturing Springer, 2010.

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Classification of AM Processes

Classification as per the ASTM – Vat photopolymerization

• Machine architecture and Powder bed fusion

AM Processes
• Materials transformation physics Material extrusion

Material jetting

Binder jetting

Sheet lamination

Directed energy deposition

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Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies: rapid prototyping to direct digital manufacturing Springer, 2010.

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Vat Photopolymerization Process

An additive manufacturing process in which liquid photopolymer in a vat is selectively

cured by light activated polymerization

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Powder bed fusion

An additive manufacturing process in which thermal energy selectively fuses regions of
a powder bed.
• Selective Laser Sintering (SLS)
• Selective Laser Melting
(SLM)/ Direct Metal
• Laser Sintering (DMLS)
• Electron Beam Melting (EBM)
• Multi Jet Fusion (MJF)

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Material extrusion - FDM

An additive manufacturing process in which material is selectively dispensed through a
nozzle or orifice.

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Material jetting
An additive manufacturing process in which droplets of build material are selectively
deposited

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Binder jetting
An additive manufacturing process in which a liquid bonding agent is selectively
deposited to join powder materials.

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Sheet lamination
An additive manufacturing process in which sheets of material are bonded to form an
object.

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Directed energy deposition

An additive manufacturing process in which focused thermal energy is used to fuse
materials by melting as they are being deposited.

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AM: Process Chain

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Generalized Process Chain

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Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies: rapid prototyping to direct digital manufacturing Springer, 2010.

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Step 1: Conceptualization and CAD

• Creation of the 3D source data –
 A design expert via a user interface
 Software as part of an automated optimization algorithm
 3D scanning of an existing physical part
 Some combination of all of these

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Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies: rapid prototyping to direct digital manufacturing Springer, 2010.

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Step 2: Conversion to STL/AMF

• Nearly every AM technology uses the STL file format.

• The term STL was derived from STereoLithograhy (3D Systems, 1990s).

• A de facto standard to describe a CAD model in terms of its geometry alone.

• Approximates the surfaces of the model with a series of triangular facets by

removing any construction data, modeling history, etc.
• The minimum size of these triangles
can be set within most CAD software

• The objective is to ensure the

models created do not show any
obvious triangles on the surface.
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Step 2: Conversion to STL/AMF

• Defect: complex and highly discontinuous geometry may result in triangle

vertices that do not align correctly.

• This may result in gaps in the surface.

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Step 2: Conversion to STL/AMF

• The triangle size: the minimum distance between the plane represented by the
triangle and the surface it is supposed to represent.

• Ensure: the minimum triangle offset is smaller than the resolution of the AM
machine.
• STL files are an unordered collection of triangle vertices and surface normal
vectors.
• Limitations of the STL file: units, color, material, or other feature information are
absent
• An international ASTM/ISO standard format: AMF file format
• AMF: Includes dimensions, color, material, and many other useful features.
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Step 3: Transfer to AM Machine and STL File Manipulation

• Once the STL file is ready (created and repaired), send to the target AM machine.
• First task: verify that the part is correct
• Visualization tool: AM system software allows user to view and manipulate the
part
• Reposition of the part or even change the orientation to allow it to be built at a
specific location within the machine.
• Copy function or completely different STL files: to build more than one part in an
AM machine at a time
• STL files scaling: to accommodate AM parts which are slightly larger or slightly
smaller than the original to account for process shrinkage or coatings

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Step 3: Transfer to AM Machine and STL File Manipulation

• 3D embossed characters: for identification and to add text and simple features to
STL formatted data

• Segmentation of too large parts

• Merging of multiple files

• All AM machines will not have all the functions

• Manipulation software: purchased or freely downloaded to manipulate the STL

file before building the part.

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Step 4: Machine Setup

• Setup parameters: specific to machine or process

• Some machines are only designed to

 Run a few specific materials
 Give the user few options to vary layer thickness or other build parameters

• Other machines are designed to

• run with a variety of materials and
• may also have some parameters that require optimization to suit the type of part
that is to be built,
• or permit parts to be built quicker but with poorer resolution.

• In the more complex cases: default settings or save files from previously defined
setups to speed up the machine setup process and avoid mistakes
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Step 5: Build
• First few stages are semi-automated: may require considerable manual control,
interaction, and decision making.

• This stage is the computer-controlled building phase.

• All AM machines will have a similar sequence of layering –

 A height adjustable platform or deposition head
 Material deposition/spreading mechanisms, and
 Layer cross-section formation

• Some machines will combine the step 2 and 3

• Repetition of laying process as long as no errors are detected during the build

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Step 6: Removal and Cleanup

• AM part should be ready for use with minimal manual intervention.
• In some cases, parts will require a significant amount of post-processing.

• For metal supports, a wire EDM machine, bandsaw, and/or milling equipment
may be required to remove the part from the baseplate and the supports from
the part.
• In all cases, the part must be either separated from a build platform or removed
from excess build material surrounding the part.

• Some AM processes use additional material other than that used to make the
part itself (secondary support materials).

• The cleanup stage may also be considered as the initial part of the post-
processing stage.
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Step 7: Post-Processing
Post-processing: refers to the (usually manual) stages of finishing the parts for
application purposes.

• Application specific stage (minimum/no post-processing/ good precision and

finish)

• May require –
 Machining (abrasive finishing - polishing and sandpapering and milling etc.)
 Chemical treatment
 Thermal treatment
 Infiltration and/or surface coatings for fragile components

• Mostly, done manually; however, use of power tools, CNC milling, and additional
equipment, like polishing tubs or drying and baking ovens
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Step 7: Post-Processing

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Step 8: Application
• Following post-processing, parts are ready for use.
• Issues in application –
 May not behave according to standard material specifications
 Failure due to small voids trapped inside them
 Degradation of material during build
 Inadequate bonding, linking, or crystallization of materials
 Anisotropic (different properties in different direction)
 Rapid cooling results in different microstructures
• Show different behaviors (better or worse) than conventional processes
• A designer should be aware of the differences and account during design stage
• Understanding recent advancements in materials and processes offers the best
approach for how to use AM for their needs
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Thank you
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