Research Plan
Title: Studies on Additive Manufacturing Processes, Materials
and Recent Developments
Abstract
Additive manufacturing (AM) or 3D printing is the most recent and revolutionary technology in
the production industry. In this method, material is added one layer upon another layer to get
the required shape and size of the object. Most complex shaped objects can be built very easily
by this technology. Additive manufacturing has the capability to reduce the supply chain by
reducing a number of processing stages of a product. Additive manufacturing technology has
evolved significantly since its introduction as Stereo lithography in 1984 by Charles W. Hull.
Today we have different types of 3D printing techniques such as polymer resin based printing
[stereo lithography (SLA or SL), digital light processing (DLP)], wire based printing [Fused
Deposition Modeling (FDM) Fused Filament Fabrication (FFF)] and powder based printing
[Selective Laser Sintering (SLS), Selective Laser Melting (SLM)] and some hybrid Additive
manufacturing like High speed sintering. Additive manufacturing has applications spread from
toy industry to Aerospace industry and from construction field to biomedical industry. Additive
manufacturing leads to "Social manufacturing" which involves customers in all stages of
product manufacturing. Most of the large scale industries are investing a large capital in R&D
for this 3D printing. Many startups are entering into the market each day. Today, bio-
compatible kidneys, bones and even hearts can be bio printed, multi-storey buildings have
already been 3D printed. Research work is being done on different Additive manufacturing
techniques, materials and process parameters. In this regarding I would like to review the
process parameters, different materials used and focuses on recent advances in additive
manufacturing (AM).
Keywords: Additive manufacturing, 3D printing, Stereo-lithography, Selective laser Sintering,
Fused deposition modeling, bioprinting.
Processes
1. Stereolithography (SLA):
Utilizes UV light to solidify liquid resin layer by layer.
High precision but limited by resin properties.
2. Selective Laser Sintering (SLS):
Uses a laser to sinter powdered materials (plastics, metals) into solid layers.
Ideal for complex geometries and functional parts.
3. Fused Deposition Modeling (FDM):
Extrudes melted thermoplastic filament through a nozzle.
Cost-effective but lower resolution compared to other methods.
4. Direct Metal Laser Sintering (DMLS):
Similar to SLS but with metal powders.
Produces strong metal parts suitable for aerospace and automotive industries.
5. Electron Beam Melting (EBM):
Melts and fuses metal powders using an electron beam.
Provides excellent mechanical properties for medical and aerospace applications.
Materials
1. Polymers:
PLA, ABS, nylon and more specialized polymers for various applications.
Advances in bio-compatible and high-temperature resistant polymers.
2. Metals:
Stainless steel, titanium, aluminum alloys and nickel-based super alloys.
Improved powder quality and alloy compositions enhance strength and
functionality.
3. Ceramics:
Used for applications requiring high temperature resistance and electrical
insulation.
Development in ceramic powders and sintering processes.
4. Composites:
Reinforced with fibers (carbon, glass) in polymers or metals.
Enhance strength, stiffness and weight properties.
Recent Developments
1. Multi-material Printing:
Integration of different materials in a single print for functional versatility.
Advances in mixing ratios and material compatibility.
2. Industry 4.0 Integration:
AM linked with digital manufacturing for enhanced automation and
efficiency.
Use of AI and IoT for real-time monitoring and process optimization.
3. Bioprinting:
Printing of living tissues and organs using bio-inks and biomaterials.
Progress in regenerative medicine and pharmaceutical research.
OBJECTIVES:
1. Process Optimization: Investigate methods to improve the efficiency, speed and
accuracy of additive manufacturing processes such as SLS, DMLS and FDM.
2. Material Development: Research new materials or enhance existing ones (polymers,
metals & ceramics) for specific applications in additive manufacturing, focusing on
properties like strength, durability and thermal resistance.
3. Multi-material Integration: Explore techniques for integrating multiple materials within
a single print, aiming for enhanced functionality and performance in manufactured
parts.
4. Industry 4.0 Integration: Study the integration of additive manufacturing with Industry
4.0 technologies, including IoT, AI and digital twins, to optimize production processes
and enable real-time monitoring and control.
5. Bioprinting and Medical Applications: Investigate bio-printing technologies for medical
applications, such as tissue engineering, organ printing, and personalized medicine.
6. Large-Scale Additive Manufacturing: Develop methodologies and materials for large-
scale additive manufacturing, focusing on applications in construction, aerospace and
automotive industries.
7. Sustainability and Environmental Impact: Assess the environmental impact of additive
manufacturing processes & materials and develop strategies to improve sustainability
through recycling, waste reduction and eco-friendly materials.
8. Quality Assurance and Standards: Establish standards and quality control measures for
additive manufacturing processes and materials to ensure consistency, reliability and
safety of manufactured parts.
9. Market Adoption and Economic Analysis: Analyze the market adoption of additive
manufacturing technologies across industries, assessing economic factors, barriers to
adoption and potential growth areas.
10. Educational and Training Initiatives: Develop educational programs and training
initiatives to enhance workforce skills in additive manufacturing technologies,
addressing the need for specialized knowledge and expertise.
Literature Survey
Journals, articles & books
1. Gibson, I., Rosen, D. W., & Stucker, B. (2015). Additive Manufacturing Technologies: 3D
Printing, Rapid Prototyping, and Direct Digital Manufacturing. Springer.
This book covers in detail the various aspects of joining materials to form parts. A
conceptual overview of rapid prototyping and layered manufacturing is given, beginning
with the fundamentals so that readers can get up to speed quickly. Unusual and
emerging applications such as micro-scale manufacturing, medical applications,
aerospace and rapid manufacturing are also discussed. It also Reflects recent
developments and trends adheres to the ASTM, SI and other standards, it also includes
chapters on automotive technology, aerospace technology and low-cost AM
technologies.
2. Campbell, I., Bourell, D., & Gibson, I. (2012). Additive Manufacturing: A Historical
Perspective. ASME Journal of Manufacturing Science and Engineering, 134(4), 041001.
The purpose of this paper is to provide a personalized view by the Editors of the Rapid
Prototyping Journal. Design/methodology/approach – It collects their years of
experience in a series of observations and experiences that can be considered as a
snapshot of where this technology is today.
3. Kruth, J. P., Leu, M. C., & Nakagawa, T. (1998). Progress in Additive Manufacturing and
Rapid Prototyping. CIRP Annals, 47(2), 525-540.
4. Leong, K. F., Cheah, C. M., & Chua, C. K. (2003). Solid freeform fabrication of three-
dimensional scaffolds for engineering replacement tissues and organs. Biomaterials,
24(13), 2363-2378.
5. Ligon, S. C., Liska, R., Stampfl, J., Gurr, M., & Mülhaupt, R. (2017). Polymers for 3D
Printing and Customized Additive Manufacturing. Chemical Reviews, 117(15), 10212-
10290.
6. Wong, K. V., & Hernandez, A. (2012). A review of additive manufacturing. ISRN
Mechanical Engineering, 2012.
7. Gu, D., Meiners, W., Wissenbach, K., & Poprawe, R. (2012). Laser additive
manufacturing of metallic components: materials, processes and mechanisms.
International Materials Reviews, 57(3), 133-164.
8. Gao, W., Zhang, Y., Ramanujan, D., Ramani, K., Chen, Y., Williams, C. B., ... & Zhao, F.
(2015). The status, challenges, and future of additive manufacturing in engineering.
Computer-Aided Design, 69, 65-89.
Books
1. Kruth, J. P., Leu, M. C., & Nakagawa, T. (Eds.). (2007). Additive Manufacturing of
Metals: The Technology, Materials, Design and Production. Springer.
2. Kalpakjian, S., & Schmid, S. R. (2014). Manufacturing Engineering and Technology.
Pearson Education.
Paper Publications
1. B Prakash, Mohd Mansoor Ahmed, S.S. Mahmood “Dynamic Analysis of Cracks in
Composite Materials” (International Journal & Magazine of Engineering, Technology,
Management and Research, Volume No: 2 (2015), Issue No: 7 (July), ISSN No: 2348-
4845)