ADDITIVE MANUFACTURING
Course Code: MF8071
Department of Mechanical Engineering
Ramco Institute of Technology, Rajapalayam
TEXT BOOKS:
1 Chua C.K., Leong K.F., and Lim C.S., “Rapid prototyping: Principles and applications”, Third
edition, World Scientific Publishers, 2010.
2 Ian Gibson, David W.Rosen, Brent Stucker “Additive Manufacturing Technologies: Rapid
Prototyping to Direct Digital Manufacturing” Springer , 2010.
REFERENCES:
1 Andreas Gebhardt “Understanding Additive Manufacturing: Rapid Prototyping, Rapid
Manufacturing”
Hanser Gardner Publication 2011.
2 Kamrani A.K. and Nasr E.A., “Rapid Prototyping: Theory and practice”, Springer, 2006.
3 Liou L.W. and Liou F.W., “Rapid Prototyping and Engineering applications :A tool box for
prototype
COURSE OUTCOME:
On completion of this course, students will learn about
Working principle and construction of Additive Manufacturing
technologies,
AM potential to support design and manufacturing,
Modern development in additive manufacturing process
Case studies relevant to mass customized manufacturing.
Mr.J.Jerold John Britto
Assistant Professor (Sr.Gr.)
Department of Mechanical Engineering
Ramco Institute of Technology,
Rajapalayam
ADDITIVE MANUFACTURING
UNIT I INTRODUCTION
Overview – Need - Development of Additive Manufacturing Technology -Principle – AM Process Chain-
Classification –Rapid Prototyping- Rapid Tooling – Rapid Manufacturing – Applications- Benefits –Case studies..
Development of Additive Manufacturing
Technology -Principle
What is Additive Manufacturing?
• The term Rapid Prototyping (or RP) is used to describe a process for rapidly creating
a system or part representation before final release or commercialization.
• A recently formed Technical Committee within ASTM International agreed that new
terminology should be adopted. Recently adopted ASTM consensus standards now
use the term Additive Manufacturing.
• The basic principle of this technology is that a model, initially generated using a 3D
Computer Aided Design (3D CAD) system, can be fabricated directly without the
need for process planning.
Additive Manufacturing – Layer Manufacturing
Additive manufacturing, also known as 3D printing, rapid prototyping or freeform
fabrication, is ‘the process of joining materials to make objects from 3D model
data, usually layer upon layer, as opposed to subtractive manufacturing
methodologies’ such as machining.
Additive Manufacturing – Layer Manufacturing
“Additive Manufacturing” (AM) is a layer-based automated fabrication
process for making scaled 3-dimensional physical objects directly from
3D-CAD data without using part-depending tools.
It was originally called “3D Printing”.
Additive manufacturing also refers to technologies that create objects,
layer by layer or sequential layering
The Generic AM Process
Generic process of CAD to part, showing all 8 stages
Additive Manufacturing Process chain
The Eight Steps in Additive Manufacture
1. Conceptualization and CAD
2. Conversion to STL
3. Transfer and manipulation of STL file on AM machine
4. Machine setup
5. Build
6. Part removal and clean-up
7. Post-processing of part
8. Application
Seven additive manufacturing processes according to ASTM Committee F42 on Additive Manufacturing. Source: Boeing/ASTM
3D Printing vs. Traditional Manufacturing
Customization Intricate Parts Prototype Cost 1st Part Lead Time
10
9 9 9
7
5 5
4
Cost/Low volume Cost/High Volume Strength Surface Finish
10 10 10
9
8
7
2
3D Printing vs. Traditional Manufacturing
Cost Cost
Conventional Production Conventional Production
3D Printing 3D Printing
No. Of Pieces Complexity Of Pieces
Different 3D Printing Techniques
FDM SLA / DLP SLS SLM
PJP Binder jet LOM CLIP
FDM SLA/DLP SLS
SLM
PJP
Laminate Object Manufacturing
Continues Liquid Interface Production (CLIP)
Binder Jet Printing
What Can Be 3D Printed
Plastics
Jewelry Health
Metals
Care Compound
Research Mtrls Fashion
Ceramic
Personalized Items Dresses, materials,
adornments
Art
Resins Hobby/
Chocolate
Gifts Accessories
Paper Food
Sandstone
Unique toys, arte-
facts, sculptures
Three Phases of Development Leading to Rapid Prototyping
First Phase: Manual Prototyping
Geometric Modeling Prototyping
• First Phase: 2D Wireframe First Phase: Manual Prototyping
Started in mid-1960s • Traditional practice for many centuries
Few straight lines on display may be: • Prototyping as a skilled crafts is:
• circuit path on a PCB • traditional and manual
• plan view of a mechanical component • based on material of prototype
“Natural” drafting technique • “Natural” prototyping technique
Second Phase: 3D Curve and Second Phase: Soft or Virtual
Surface Modeling Prototyping
• Mid-1970s • Mid-1970s
• Increasing complexity • Increasing complexity
• Representing more information about precise shape, size and • Virtual prototype can be stressed, simulated and tested,
surface contour of parts with exact mechanical and other properties
Third Phase: Solid Modeling Third Phase: Rapid Prototyping
• Early 1980s • Mid-1980s
• Edges, surfaces and holes are knitted together to form a • Benefit of a hard prototype made in a very short
cohesive whole turnaround time is its main strong point (relies on CAD
• Computer can determine the inside of an object from the modeling)
outside. • Hard prototype can also be used for limited testing
• No longer ambiguous but exact • Prototype can also assist in the
manufacturing of the products
Industries Implementing 3D Printing
Jewelry Health Care Research Fashion
Personalized Items Guides, Prosthetics High precision parts Dresses, Ornaments
Art Hobby/ Gifts Accessories Food
Unique toys, Sculptures Personalized Gifts Custom fit shoes… Various food items
Case Study 1 – Personal Memento
Step 1 : Concept Design Step 2 : Part Creation
Step 4 : Finishing Step 3 : Assembly
Case Study 2 – Industrial Layout
Step 1 : Aerial Survey Step 2 : Topography
Step 4 : Finishing Step 3 : Elements Printing
Case Study 3 – Fiber Mould Batch Production
Step 1 : Concept Step 2 : 3D Design
Step 4 : Batch Production Step 3 : 3D Print
The Rapid Prototyping Wheel depicting
the four major aspects of RP
Results of the integration of RP technologies
Classification of Additive Manufacturing Technology
Materials for Additive Manufacturing Technology
Tooling
Applications
Seven sub-categories of software that are applicable to Additive Manufacturing, sorted
by the need into four main categories
