Additive Manufacturing

Topics covered in the present class

Introduction to Additive manufacturing technologies for polymers

• Extrusion based systems: Basic principles of

extrusion-based system,

• Plotting and path control,

• Fused Deposition Machines (FDM),

• Types of FDM,

• Materials for FDM.

Additive manufacturing technologies: rapid prototyping to direct digital

manufacturing, Ian Gibson, David W. Rosen, Brent Stucker, Springer, 2010.
 AM Processes Classification
As per ASTM F42, AM processes are classified into 7 catagories

1) Vat Photopolymerisation

2) Material Jetting

3) Binder jetting

4) Material extrusion

5) Powder bed fusion

6) Sheet lamination

7) Directed energy deposition

 Material extrusion based AM Processes
Fused Deposition Modeling (FDM) The Concept – Shapes from Ropes
 Contd.

Fused Deposition Modeling (FDM)

Processes is similar to JELEBI making!
Introduction

• Molten material comes out of a nozzle, falls on the base material and solidifies
• Comes out as a fluid rope, takes the desired shape and solidifies
• Molten material inside a hot chamber is extruded through a nozzle
• Explicit support structures are required. Therefore, twin heads are used, one for
model and the other for support.
Fused Deposition Modeling (FDM)
 Fused Deposition Modeling (FDM)
The problem of Support Mechanism
 Contd.
Fused Deposition Modeling (FDM)
Technical Name

• Overhanging features
• How to decide: when seen from above, if all surfaces are visible, no overhang.
• Mathematical Definition: if a surface has a –ve 𝑘 component
Fused Deposition Modeling (FDM)
ASCII Stl format
solid T
facet normal 0.000000e+00 0.000000e+00 -1.000000e+00
outer loop
vertex -2.615836e+01 2.314307e+01 -1.500000e+02
vertex -1.000000e+02 2.314307e+01 -1.500000e+02
vertex -1.000000e+02 7.430143e+01 -1.500000e+02
endloop
endfacet

.
.
.

facet normal 0.000000e+00 0.000000e+00 -1.000000e+00

outer loop
vertex 2.500000e+01 2.314307e+01 -1.500000e+02
vertex -2.615836e+01 2.314307e+01 -1.500000e+02
vertex -1.000000e+02 7.430143e+01 -1.500000e+02
endloop
endfacet
 Contd.
Fused Deposition Modeling (FDM)

Toolpath generation

Some sample parts

 Contd.
Fused Deposition Modeling (FDM)
Process

1- Pre-Process 2- Manufacture 3- Remove Supports

 Contd.
Fused Deposition Modeling (FDM)
Steps
• The twin heads can be moved in X and Y directions. The table in which building is done can be moved in Z direction.

• Slicing is done and regions of support requirement are identified.

• The parameters like layer thickness, roadwidths for both heads, number of layers for base etc. are input.

• Finally the paths for both model and support heads are calculated. Path of each layer is checked for open loops and other

defects and corrected.

• The machine uses separate head for each material. The appropriate head is loaded. Nozzle of the required diameter is set.

(These need not be done for every part.)

• The spools of appropriate model and support materials are loaded.

• In modern machines, there will be pairs of cartridged intelligent spools for model and support and they can switch

automatically. No longer user has to insert the wire and purge it.
 Fused Deposition Modeling (FDM) Contd.

Steps
• Set the temperature on both chambers and working volume. It is 270°C for model, 265°C for support and 70°C for the

working volume. Allow time so as to reach these stable conditions.

– The chamber temperature ensure that the respective material is heated with the exact overheat. More temp will

cause over penetration into the subtrate and remelting; less temp will cause poor flow and adhesion with the subtrate.

– The temperature in the working volume ensures that the substrate is at the required condition.

• Of late, these also get set automatically by reading the bar code on the spools.

First a hardfoam is mounted on the table. Purge to see that both nozzles are in good condition. Smooth purging indicates

that the parameters are correct and the material is within its shelf-life.

• Of late, instead of foam, a persbex sheet is used. The persbex sheet is held by vacuum.
 Fused Deposition Modeling (FDM) Contd.

Steps
Jog to bring the nozzle to just touch the foam surface. Start the process. First a few layers of support is deposited to create a
base of the build. After that the following steps are repeated for each layer:

• Model material is deposited. Material deposited is in the form of a ribbon of rectangular crosssection of „slice thickness x
road width“. First the outer contour is made followed by area filling inside in a zig-zag manner. The angle of zig-zag
pattern can be set or it can be randomized for all the layers. Randomizing will improve the homogeneity of the prototype.

• Wherever support is required, the support head deposits material there. This will be coarser than model material so that it
can be easily removed.

• Once in a while, the nozzle goes and rubs on a brush to clean itself. This is called purging.
 Fused Deposition Modeling (FDM) Contd.

Steps

After building take out the foam along with the part.

• Supports are removed carefully. This will be fairly easy except for interior features since
– support material has poor adhesion with model material
– It is weak due to coarse deposition
– It has a different color.

• Note: They have also introduced water-soluble support material.

• The part is finished and painted as required.

 General Materials Used in FDM
Materials Used

• ABS –Acrylonitile Butadiene Styrene or 'lego' plastic – a very common choice for 3D printing.

• PLA – Polylactic Acid – Is available in soft and hard grades, is becoming very popular and may overtake

ABS in the near future.

• PVA - Polyvinyl Alcohol – This is used as a dissolvable support material.

• PC – Polycarbonate – Polycarbonate requires high-temperature nozzle design.

• SOFT PLA – Polylactic Acid – Is rubbery and flexible, available in limited colors and sources.
 Fused Deposition Modeling (FDM) Contd.

Advantages & Limitations

Advantages
• Any thermoplastic material can be used as long as the appropriate head is available. The parts are very strong.
• It does not employ lasers and hence no safety related issues. It does not use liquid/ powder raw materials and hence
clean. It can be kept in an office environment as a 3D printer.
• Very easy to remove the support. This is probably the easiest of all AM processes.
• This is the cheapest machine. However, this is also due to their business policy since the costs of all AM machines are
comparable.

Limitations
• As every point of the volume is addressed by a “mechanical device”, it is very slow.
• Not very accurate compared SLA, SGC etc.
• Not isotropic.
 Other Similar Processes
Sander’s Model Maker

In principle, this is also an extrusion process like FDM.

• Wax is the primary material.

• Popular for jewelry manufacture.

• Layer is machined to maintain the thickness accurately.

• SEEPZ alone has about 5 such machines

Extrusion based Bio Printing for Human Organs
Extrusion based Bio Printing for Human Organs