Additive Manufacturing – Basics/Introduction

K. G. Prashanth
Department of Mechanical and Industrial Engineering, Tallinn University of Technology, Tallinn, Estonia
 Outline

- Introduction Additive Manufacturing

- Additive Manufacturing Processes

- AM Applications

- When to use AM

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 Manufacturing Processes
Definite component  Manufacturing process  combines raw matarial to an useful
component

subtractive manufacturing (SM) additive manufacturing (AM) /

solid free form processing (SFF)
process of removing undesired layer of material in
a controlled way to produce a desired object – process of joining materials by fusing / binding /
may result in high cost and environmental issues solidifying resin / powder usually layer by layer,
from 3D CAD data
Machining processes – cutting, turning, milling,
boring, drilling, boring, reaming, tapping etc. Stereolithography, 3D printing, selective laser
melting (SLM), selective laser sintering (SLS),
selective mask sintering, electron beam melting,
digital light processing, ultrasonic consolidation etc.

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 Geographical and geometrical flexibility

Flexibility in manufacturing (both geographical and geometrical)

Anyone can build any part at any location at any time (electricity, raw materials & Computer)

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 AM in nature

Shaping of objects by successive addition of material...

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 Traditional AM Processes
Ancient / traditional

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 AM definition
Additive Manufacturing (AM) – Process by which digital 3D design data is used to build up a component in layers by
depositing material

3D printing is used for AM

However, AM is more accurate in – describes a professional production technique which is clearly distinguished from
conventional methods of material removal

ASTM Committee
Additive Manufacturing Technologies/F42
Aerospace and Aircraft/F07
Aircraft Systems/F38
Fatigue and Fracture/E08
General Aviation Aircraft/F44
Medical and Surgical Materials and Devices/F04
Metal Powders and Metal Powder Products/B09
Plastics/D20
Unmanned Aircraft Systems/F38

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 AM Classification

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 Classification

Additive Manufacturing

Single step AM Process Multi step AM process

Fusion of similar materials Adhesion of metals +

Secondary processing
Metallic Polymer Ceramic Composite
Metallic Ceramic Composite

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 Single step AM processes
Single step AM processes

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 Powder bed fusion processes

Powder bed + Selective meting (by thermal energy)

Thermal Sources
 Electron Beam (EBM – Electron Beam Melting process)
 Laser Beam (SLM – Selective Laser Melting process)

Several commercially available equipments for SLM (SLM Solutions, EOS, Concept Laser, Realizer, Renishaw, 3D systems,
etc.) – relatively slow process, dimensional accuracy and flexible design.
EBM – ARCAM (Fast process, hot chamber, difficult to remove powder from hallow sections...)

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 Multistep AM processes
Multi step AM processes

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 Cost factor

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 AM – practical issues

3D printing is not standardized

 Customized parts inexpensively

 Cost to Quality!

 3D printing vs traditional manufacturing – installation cost

 Lack of universal standards

 Consistency in quality and process parameters

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 AM – practical issues

High equipment and product costs

 0.5 million – small metal 3D printer

 High costs – large production volume

 Slow process

 Days for bigger components

 Quality a concern

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 AM – practical issues

3D printing knowledge gap

 Innovations every other day!

 Designer + Scientists + Technicians

 Future employees…!

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 AM – practical issues

Intellectual property complications

 Value chain – shifting the value of object itself to design

 Design – if not protected – security concerns and liability issues

e.g. weapons

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 AM – practical issues

https://www.jabil.com/insights/blog-main/overcoming-top-3d-printing-challenges.html

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 AM – practical issues – Material challenges
SLM material

Al-based Fe-based Ti-based Other alloys

(1) Nitinol – shape
memory alloy
(2) CoCr Mo
Pure Fe SS Maraging Metallic glass (3) Ni-based (IN 718,
316L Steel 625 & Metallic
glass)
(4) Zr-based glass
Pure Ti Ti6Al4V Ti-Nb
Ti-Al
Composites
Al-Si system Al-RE-TM 2XXX 7XXX Composites
Quasicrystals

Al-12Si AlYNiCo
Al-10Si-Mg AlGdNiCo

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 AM – practical issues – material challenges

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 Disadvantages of AM

- High energy consumption - Surface finish

- Part cost (Expensive) – experimental use and material cost

- Material limitations - Dimensional control

- User friendliness?

- Harmful emissions

- Process speed - Size limitations

- Copyright infringements

- Job loss (manufacturing)

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 AM – pros and cons

- Freedom of design at low cost (no restriction - Unexpected pre- and post-processing
with shape)
- Increased processing cost
- Rapid iteration through design permutation
- Lack of industrial standards
- Excellent mass customization
- Low speed (Mass production)
- Elimination of tooling
- Inconsistent material
- Green manufacturing
- Limited materials
- Minimal material waste
- High equipment cost for high end
- Personalized manufacturing manufacturing

- No assembly needed - Property concerns

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 AM – gaps and needs

Material Modeling
Design Characterization
development monitoring
methodology and
and control and
and standards certification
evaluation processes

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 AM – Material and Process Consideration
- Absorptance ( rate of absorbed to incident radiation – proportional – optical penetration depth

- Optical penetration depth – depth at which the intensity of the radiation inside the material falls to
appx. 37% of the original value

- Surface tension

- Wettability

- Viscosity

Process planning
 Orientation of parts

 Support Design

 Slicing and scan path

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 Applications

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 When to use AM
Improved functionality (light weight structures, conformal cooling channels, material
reduction...)

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 When to use AM
High manufacturing cost due to processing (complex structures)

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 When to use AM
Saving assembly costs

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 When to use AM

Reduced lead time

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 When to use AM
Inventory cost

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 When to use AM
Materials saving

ρrel = 24 % ρrel = 12 % ρrel = 4 %

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