© Bradley Jared, 2023

Principles of Additive Manufacturing

ME 469/569, Fall
Dr. Bradley Jared
AM Overview

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 © Bradley Jared, 2023

Definition
• ISO/ASTM 52900:2021
• Additive manufacturing (AM), n
— process of joining materials to make parts
from 3D model data, usually layer upon
layer, as opposed to subtractive
manufacturing & formative manufacturing
methodologies
• Implies “digital” at multiple levels
— representation, controls, metrology
— voxel level material access
Additive manufacturing vs. 3D printing, SME

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Terminology
"#3DBenchy 3D-printed on a Zortrax M200 3D-
printer in ABS plastic - By Creative-Tools.com"

• Is AM distinctive?
— 3D printing
— rapid prototyping (RP)
— freeform fabrication
— specific processes "Medical researchers turn to 3-D printing
for rapid prototypes" by U.S. Army Combat
Capabilities Development Command

• Manufacturing!
— to make into a product suitable for use*

"GE Additive: Additively manufactured cleat positioned between shoe

and pedal on Stevin Creegan’s race bike. (Photo: GE Additive,
GEADPR040)" by PressReleaseFinder

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* Merriam-Webster.com
 courtesy: Joe Beaman, UT Jared,
© Bradley Austin 2023

History
Baker, US Patent
• 1892: Blanther’s wax layer topo relief map 1,533,300, 1925

• 1925: Baker using electric arc & electrodes

• 1968: Swainson proposed curing polymers w/lasers
• 1972: Matsuba cured photopolymer resin layers 1st SLS part
• 1984: Hull created stereolithography
— 1987: 3D Systems released STL file format 1st stereolithography system,
Chuck Hull, 3D Systems, Springer
• 1986: Deckerd & Beamon demonstrated polymer selective laser sintering
— 1992: DTM Corp formed to develop metal laser sintering
• 1989: MIT patented 3D Printing (3DP) / binder jetting process
• 1990: EOS formed to develop direct metal laser sintering
• 1997: Arcam AB formed to develop electron beam melting
• 1998: Sandia licensced LENS to Optomec Inc.
• 2013-2015: 16 key technology patents expire (stereolithography, SLS,
FDM, ink jet)
— 2009: Makerbot founded, Cupcake CNC released

https://commons.wikimedia.org/wiki/File:MakerB
ot_ThingOMatic_Bre_Pettis.jpg#/media/File:Mak
4 erBot_ThingOMatic_Bre_Pettis.jpg
 © Bradley
Courtesy: Scott Brill, Jared, 2023
Seekraz.wordpress.com

Add Value Courtesy: David Gill, SNL

TO bar for a torsion load case (left) resembling a cholla cactus

• Design
(right)

— complex geometries
• freeforms, internal structures
• light-weighting / TO
• integration Courtesy: GE
Additive

GE design winner w/84% weight reduction that meet load requirements

GE LEAP
engine fuel
nozzle
replaced
20 parts,
reduce
weight available features w/additive manufacturing
75%
Courtesy: GE Additive

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Courtesy: HRL Laboratories, LLC DeHoff, Mat Sci

Add Value
Tech, 2014

• Design
— complex geometries grain texture control in Inconel 718 via EB-PBF

• freeforms, internal structures

• light-weighting / TO
• integration
— complex materials powder DED
multi-
• microstructures, gradients, multi-materials material
structures
• hierarchical materials
metal
microlattice on
a dandelion Griffith, Proc of SFF, 1997

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 Sandia Hasbro © Bradley Jared, 2023
Hand, 50% Selfie Series
built w/AM,
cost ~$10k,

Reduce Risks embedded

sensors

• Accelerated cycles
— development: rapid prototyping (RP)
• simultaneous design iterations
• small lot / rapid turn times
— manufacturing: AM
• mass customization
• near-net material preforms
• Reduced costs acetabular hip Amplify Additive

— nonrecurring engineering & fabrication cup replacement

reduce time to
• molds, fixtures, tooling, programming
market up to
— material use (buy-to-fly) 58%
— integration removes parts & process steps
— capital
• Business case is critical, and often underappreciated
— becoming increasingly scrutinized

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 Relativity Space © Bradley Jared, 2023

Applications 11’ tall fuel

tank on
Stargate
printer
• Wide spread growth & use
— aerospace, defense, automotive,
healthcare, consumer Watkins, Adv Mater Processes,
2013
— products span scales & materials
• Development Divergent
3D
Sourced Blade chassis C.C. Weiss / New Atlas

— prototyping & testing Adidas.com

— tooling, fixturing
• Limited quantity production
— First Launch: Terran 1
• Part repair, refurbishment &
repurposing nearly 100% of custom
hearing aids are printed
4D Fusio

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Global revenue for AM
products & services
Wohlers, 2023

Market Trends
• Democratization of manufacturing
— maker movement
— mass customization
— point source manufacturing / reshoring

• Global manufacturing market

— Wohlers Report, 2023 Global AM revenue,
Wohlers, 2023
— $18B in 2022, 18% growth
• >20% average growth since 2010
• covers equipment, products & materials
— 3D Printing Trends: Six Major
Developments

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EBM part
solid
model

Challenges
Objet part

• Geometry
— accuracy
• print & material
• part deformation / stresses
— surface finish
• post-process finishing common FDM surface texture,
Ra = 55 µm

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Challenges
• Materials
— relatively limited alloy / composition options
— more expensive feedstock courtesy: Albert To , U Pitt

— property differences: defects, microstructures

• Processes
— mainly open loop
— serial, low volume throughput
— post-processing
• part cleaning, support removal, thermal treatments
WAAM internal porosity
from gas blow thru

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Challenges
• Qualification
— design
• definition: complex geometries, lattices, multi-material,
gradients
• tolerances: how to inspect?
• files: difficult to generate, transmit, translate, analyze,
store
— part acceptance
• inspection, validation, verification
• metrology: cost / access / resolution / scale
• material assurance: material & geometry formed
simultaneously
• metrology of complex & internal geometries
— process characterization & certification
LENS functionally graded materials
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LithaBone HA 400, hydroxyapatite
bioresorbable implant

Research Needs
• Materials
— new alloys
— multi-materials
• tailored, gradient, multi-functional
— performance
• Process courtesy:

— controls XJet

— scale
— new methods
• Metrology
— acceptance / qualification
• Design
— TO, hierarchical materials nanoparticle
jetting

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Where is AM Headed?
• Will supplement & complement (not necessarily
supplant) most traditional mfg cycles
— clear for near term, unclear for future
— industries w/high price, low throughput, customization AMMONITE, Fernando Romero
at risk
— value add must drive adoption

• Mass customization is a game changer

— already seen in medicine, dentistry, art, fashion
— product on demand

• Dynamic industry, improvements will continue…

— LOTS of research opportunities & direction Relativity
Space

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Where
else?

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Homework: Read AMT Ch. 1-3

Questions?