GI 4A IPID Invited Lecture 1
Additive Manufacturing of Composite
Materials
Dr Ramu Murugan
Adjunct Professor-School of Industrial Engg., Grenoble INP
Associate Professor, Department of Mechanical Engineering, Amrita
School of Engineering, Coimbatore, Amrita University, India
Mail:
[email protected],
[email protected]Whatsapp: (+91)9865897767
Specialization : Additive Manufacturing of polymeric materials,
Composite Materials, Finite Element Analysis and Engineering Design
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Source: https://aethon.com/mobile-robots-and-industry4-0/
Introduction to Additive Manufacturing Process
What is Additive Manufacturing?
It is a manufacturing process in which 3D CAD
model is used for building component by
depositing materials in layers
Additive Manufacturing commonly referred as
3D Printing
Source: https://manufactur3dmag.com
Source: https://www.3dnatives.com/
Additive Vs Subtractive Machining
• Material
• Speed
• Easy of use
• Accuracy
• Size limitation
• Geometric complexity
• Cost
History of AM
• In 60s Herbert Voelcker thoughts of the possibilities of
using computer aided machine control to run machines
that build parts from CAD geometry
• During 70s, he developed the mathematics to describe
3D aspects that resulted in the first algorithm for solid
modeling
• In 80s, Carl Deckard came up with the idea of layer
based manufacturing
• Charles Hull took the credit for development of a
additive manufacturing system(Stereolithography)
during 1986
Additive Manufacturing
Hopkinson and Dickens’ classification
• Stereolithography
Liquid Based • Jetting Systems
• Direct Light Processing
• Selective Laser Sintering
• Three-Dimensional Printing
• Fused Metal Deposite Systems
AM Processes • Electron Beam Melting
Powder Based • Selective Laser Melting
• Selective Masking Sintering
• Selective Inhibition Sintering
• Electro photographic Layered
Manufacturing
• High Speed Sintering
• Fused Deposition Modelling
Solid Based
• Sheet Stacking Technologies
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ADDITIVE MANUFACTURING http://wpcontent.answers.com/wikipedia/commons/thumb/9/9c/Rapid_prototyping_slicing.jpg/400px-Rapid_prototyping_slicing.jpg
Rapid Prototyping in a nutshell
1. 3D CAD model of the desired object is generated
2. The CAD file is typically translated into STL* format
3. The object described by the STL file is sliced along
one direction (the ‘z’ or ‘printing’ direction)
4. Each slice is manufactured and layers are fused
together (a variety of techniques exist). The material
can be deposited by dots (0D), lines (1D) or sheets
(2D)
*The STL (stereo lithography) file format is supported by most CAD packages, and is is widely used in most
rapid prototyping / additive manufacturing technologies.
STL files describe only the surface geometry of a three dimensional object without any representation of
color, texture or other common CAD model attributes. The STL file describes a discretized triangulated
surface by the unit normal and vertices coordinates for each triangle (ordered by the right-hand rule).
*Source: ENG 165-265Spring 2017, Dr. Marc 14
Madou
Advantages of AM
• Complex geometry with no additional costs
• Build speed; reduction of lead time
• No expensive tooling required
• Dimensional accuracy
• Wide range of materials(polymer, ceramic,
metal,..)
• Green manufacturing
Limitations of AM
• Part size
• Most suitable for mass
customization rather than mass
production
• Materials: Non weldable
materials are difficult to
process by AM
• Properties: Could achieve
99.9% density with some
residual porosities
• Inferior than cast/wrought
metals
Case Studies of AM
Aerospace Industry
• The engine for Orbex Prime has been 3D printed by SLM Solutions on an SLM 800 large
format additive manufacturing system
• it is made in a single piece, eradicating joins and strengthening the part’s overall integrity
• It is made from nickel alloy, and its additive production has saved Orbex 90% in turnaround
time and over 50% in costs compared to traditional CNC machining.
• The engine reportedly helps make the Prime “30% lighter and 20% more efficient than any
other launch vehicle in its category
Source: https://3dprintingindustry.com/news/slm-solutions-3d-prints-landmark-single-piece-
rocket-engine-for-orbex-148726/
Biomedical applications
Pharmaceutical Industry
• 3D Printing of personalized
medicine
• Producing controlled
release tablets
Additive Manufacturing
The assembly can be personalised
and printed in one process.
Food 3D printer
Concrete Printer
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