Additive Manufacturing
MMT 558
Lecture -2
Introduction to Additive Manufacturing
Dr. Manjesh Kumar
Assistant Professor
Department of Mechanical Engineering
SRM University AP
Andhra Pradesh ‒ 522502, India
Contact No. +918100804553
Email : manjesh.k@srmap.edu.in,
phdmanjesh@gmail.com 1
2
Contents
❑ Term of Reference
o Definitions
❑ Capabilities of Additive Manufacturing
o Geometric Capabilities
o Material Capabilities
❑ Classification of Additive Manufacturing
o ASTM
o Based on Type of Raw Stock Material
3
Introduction to AM
Term of Reference
3D 3D Printing Stereolithography
Additive Layer Manufacturing (ALM),
AM Additive Manufacturing Additive Digital Manufacturing (ADM)
Layer Based Manufacturing,
LM Layer Manufacturing Layer Oriented Manufacturing,
SFF Solid Freeform Fabrication
DM Digital Manufacturing Digital Mock-Up
RP Rapid Prototyping/Tooling/Manufacturing
Direct Manufacturing,
Direct Tooling
4
Introduction to AM
Term of Reference: 3D Printing
The term 3D Printing is as easy and simple as 2D printing.
2D printer 3D printer
Introduction to AM 5
Term of Reference
3D 3D Printing Stereolithography
Additive Layer Manufacturing (ALM),
AM Additive Manufacturing Additive Digital Manufacturing (ADM)
Layer Based Manufacturing,
LM Layer Manufacturing Layer Oriented Manufacturing,
SFF Solid Freeform Fabrication
DM Digital Manufacturing Digital Mock-Up
RP Rapid Prototyping/Tooling/Manufacturing
Direct Manufacturing,
Direct Tooling
Introduction to AM 6
Term of Reference: Additive Manufacturing
“Additive Manufacturing” refers to the layer-by-layer fabrication
of three-dimensional physical models directly from computer- Pre-process(tessellate, slice,
aided design (CAD). It is an automatic process of manufacturing support)
objects (parts, prototypes, tools and even assemblies) directly
from their CAD models without any cutters, tools or fixtures
specific to the object geometry.
Build part
(additive/stacking)
CAD file STL file Sliced file
Post-process (break
support, finish)
Introduction to AM 7
Term of Reference
3D 3D Printing Stereolithography
Additive Layer Manufacturing (ALM),
AM Additive Manufacturing Additive Digital Manufacturing (ADM)
Layer Based Manufacturing,
LM Layer Manufacturing Layer Oriented Manufacturing,
SFF Solid Freeform Fabrication
DM Digital Manufacturing Digital Mock-Up
RP Rapid Prototyping/Tooling/Manufacturing
Direct Manufacturing,
Direct Tooling
Introduction to AM 8
Term of Reference
3D 3D Printing Stereolithography
Additive Layer Manufacturing (ALM),
AM Additive Manufacturing Additive Digital Manufacturing (ADM)
Layer Based Manufacturing,
LM Layer Manufacturing Layer Oriented Manufacturing,
SFF Solid Freeform Fabrication
DM Digital Manufacturing Digital Mock-Up
RP Rapid Prototyping/Tooling/Manufacturing
Direct Manufacturing,
Direct Tooling
Introduction to AM 9
Term of Reference: Digital Manufacturing
DM are the set of technologies those can reduce the product development time and cost as well as
capable of addressing the need for customization, increased product quality, and faster response
to the market.* A Manufacturing Technology can be called as Digital manufacturing if it is centered
around a computer system.→ AM technologies fulfill this criterion.
Generic method of Additive Manufacturing (Liou, 2008)
* Chryssolouris, George, et al. "Digital manufacturing: history, perspectives, and outlook." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering
Manufacture 223.5 (2009): 451-462.
Introduction to AM 10
Term of Reference: Digital Manufacturing
Like a digital image is composed of picture elements,
also known as pixels. The same analogy is can be
extended for STLs.
This format uses a series of linked triangles to
recreate or reproduce surface geometry of
the 3D model. The more triangles used, the higher Also, the objects are fabricated by joining the thin
resolution the 3D model will have. STL file is layers by a suitable method therefore the method
widely used because it is simple, light and easy to be of producing the product is generic and
handled by 3D machines and software. completely automatic.
Introduction to AM 11
Term of Reference
3D 3D Printing Stereolithography
Additive Layer Manufacturing (ALM),
AM Additive Manufacturing Additive Digital Manufacturing (ADM)
Layer Based Manufacturing,
LM Layer Manufacturing Layer Oriented Manufacturing,
SFF Solid Freeform Fabrication
DM Digital Manufacturing Digital Mock-Up
RP Rapid Prototyping/Tooling/Manufacturing
Direct Manufacturing,
Direct Tooling
Introduction to AM 12
Term of Reference: Rapid Prototyping/Tooling/Manufacturing
Definition of
product Complete
CAD of
a car
Final product
Concept design Accurate
and evaluation
Sketch of
Iterate
a Car
Foam model
Design analysis of a car
Physical
Virtual
Prototype
3D CAD model and design Rough
documentation Component
Concept design Primary design Detailed design Detailed for mfg 13
(DFM)
Simulate realistic Simulate
appearance functionality Simulate mfg
process
Virtual Reality (VR)
Virtual Prototyping (VP)
CAD Physical model
3D geometry model
Rapid Prototyping (RP)
3D geometry model
Rapid Tooling (RT)
RE, CT, MRI
Manufacturing (RM ?)
Available Object
M01 L01: Contents 14
❑ Term of Reference
o Definitions
❑ Capabilities of Additive Manufacturing
o Geometric Capabilities
o Material Capabilities
❑ Classification of Additive Manufacturing
o ASTM
o Based on Type of Raw Stock Material
Introduction to AM 15
Capabilities
“Additive Manufacturing” refers to the layer-by-layer fabrication of three-dimensional physical
models directly from computer-aided design (CAD). It is an automatic process of manufacturing
objects (parts, prototypes, tools and even assemblies) directly from their CAD models without
any cutters, tools or fixtures specific to the object geometry.
Geometric Capabilities Material Capabilities
Objects of any kind of geometric (direct assemblies, conformal, custom, complex) or material (any
variety – poly/metal/ceramic, non-equilibrium, gradient – mono/composite/gradient, porous/lattice,
soft/hard) complexity can be produced.
Introduction to AM 16
Capabilities: Geometric Capabilities
Direct assembly
Introduction to AM 17
Capabilities: Geometric Capabilities
Conformal cooling channel
Introduction to AM 18
Capabilities: Geometric Capabilities
Mass customization
Introduction to AM 19
Capabilities: Geometric Capabilities
Density-based FGM through AM
Complex lattice structures
Introduction to AM 20
Capabilities: Material Capabilities: Non Metals
• Photopolymer
• Acrylate Resin
• Bio-based Acrylate • Dicalcium phosphate anhydrous
• Polystyrene, Polyamides calcium carbonate
• Thermoplastic polymers • Silica (SiO2),calcium carbonate
• Acrylonitrile-Butadiene-Styrene (CaCO3)
Polymers (ABS) • Calcium silicate
and • Poly-Carbonate (PC) Ceramics • Eggshell
Composites • Polylactic Acid (PLA) • Akermanite
• Nylon6 based Nano Composite • Alumina ceramic with CaSo4 and
• Carbon fiber reinforced PLA dextrin
• Fibre reinforced hydrogel • Ceramic Matrix Composite
• Alumina powder reinforced • Polymer derived ceramic
polymer matrix
• Glass fiber reinforced polymer
Introduction to AM 21
Capabilities: Material Capabilities: Non Metals
• Cement
• Concrete
Construction • Fiber reinforced concrete
• Portland cement and calcium aluminate
• Polymer Foam
• Bioinks
• Cell-laden hydrogels
• Cell/ tissue spheroids
• Decellularized Matrix Components
Biomaterials and Food • Drugs and Pharmaceutical Materials
• Acetaminophen
• Anhydrous Theophylline
• Caffeine
• Chocolate, Dough, Cheese, Powdered Sugar,
Sauce, etc.
Introduction to AM 22
Capabilities: Material Capabilities: Metals
• Copper
Pure • CoCrCuFeNiAl
• Gold
Metals
• Titanium • CoCrCuFeNiAl
High Entropy Ti
Alloys • CoCrFeNi
• Ti6Al4V • ZrTiVCrFeNi
• SS 316L • TiZrNbMoV
• Austenitic stainless steel
• Maraging steel
• Precipitation hardenable stainless
Metal steels
Alloys • H13 Tool Steel • Fe-V
• AlSi10Mg • Ni-Fe-Mo
• AlSi12 Magnetic Alloys
• Fe-30%Ni
• Inconel 625 (IN-625) • Fe-Si-B-Cu-Nb
• Inconel 718 (IN-718)
• WC-12%Co
Introduction to AM 23
Capabilities: Material Capabilities
Functionally Graded Material (FGMs)
Introduction to AM 24
Capabilities: Material Capabilities
Colourful Object
Introduction to AM 25
Capabilities: Material Capabilities
3D Printing Spatially Varying Color and Translucency
A. Brunton, C.A.N.A. Arikan, T.M. Tanksale, F. Igd, 3D Printing Spatially Varying Color and Translucency, 37 (2018)
M01 L01: Contents 26
❑ Term of Reference
o Definitions
❑ Capabilities of Additive Manufacturing
o Geometric Capabilities
o Material Capabilities
❑ Classification of Additive Manufacturing
o ASTM
o Based on Type of Raw Stock Material
Introduction to AM 27
Classification: ASTM
1 Vat Photopolymerization
5 Sheet Lamination
2 Material Jetting
6 Powder Bed Fusion
3 Binder Jetting
7 Directed Energy Deposition
4 Material Extrusion
Introduction to AM 28
Classification: ASTM: Vat Polymerization
Introduction to AM 29
Classification: ASTM: Material Jetting
Introduction to AM 30
Classification: ASTM: Binder Jetting
Introduction to AM 31
Classification: ASTM: Material Extrusion
Introduction to AM 32
Classification: ASTM: Sheet Lamination
Introduction to AM 33
Classification: ASTM: Powder Bed Fusion
Introduction to AM 34
Classification: ASTM: Directed Energy Deposition
Introduction to AM 35
Classification: ASTM
Vat Photo Material
Material Jetting Binder Jetting Sheet Lamination
Polymerization Extrusion
ASTM categorizes 7 basic AM processes
Multiple variations of these 7 AM processes exists the
core idea is same
Powder Bed Direct Energy
Fusion Deposition
Introduction to AM 36
Classification: Based on Raw Material
Type of Raw-stock
Liquid Solid Gas
Not Yet
Rapid
Photopolymer
Freezing
SLA RF
Sheet Powder Wire
LOM 3DP, SLS, DED FDM, WAAM
Course Structure 37
Fundamentals of Additive Manufacturing
M1 Introduction to Additive Manufacturing
M2 Computer Aided Process Planning for Additive Manufacturing
M3 Liquid Additive Manufacturing
M4 Sheet Additive Manufacturing
Live Demonstration of M5 Wire Additive Manufacturing
5 AM Technologies
M6 Powder Additive Manufacturing
Thank You
