Additive Manufacturing Technology

Vishesh Thakur Singh 10881A0460Supervisor: Mr. S.Rajendar, Associate Professor

What is it all about?

•The fundamental purpose of a additive manufacturing is to quickly convert a thought into a physical object.

•Transform an IDEA into REALITY

Introduction•Build physical models of objects by laying down successive layers of materials.

•Also known as rapid prototyping

•Developed to surmount the crisis of physical prototypes.

• The basic principles include materials cartridges, flexibility of output.

Terminology•The term additive manufacturing refers to technologies that create objects through sequential layering.

• An automated method whereby physical objects are swiftly made on a reasonably sized machine connected to a computer containing blueprints for the object.

•Saves time and cost.

Evolution of Additive Manufacturing

3D printer arrives

Improved performance, affordability and color

Focus on ease of use

The Algorithm

1.Pre-Process 2.Produce Part 3.Post-Process

How does Additive Manufacturing work??

3D Printers are machines that produce physical models from digital data by printing layer by layer.

It can make physical models of objects either designed with a CAD program or scanned with a 3D Scanner.

It Begins with a Digital File

1. •In the 3D world, a 3D printer needs to have instructions for what to print.

2.•It needs a file as well. The file — a

Computer Aided Design (CAD) file.

3. •The software slices the design into thousands, of horizontal layers.

4. •These layers will be printed one atop the other until the 3D object is done.

5. • a perforated platform is positioned just below the surface of a vat of liquid photo curable polymer.

6. •UV rays are allowed to pass over the surface to harden.

7. •The perforated platform is then lowered very slightly and another slice is traced out and hardened by the laser.

8. •Another slice is then created, and another until the entire object is complete.

The Product Development cycle

Preparation

PrintingDepowdering

/recycling

How Different??Additive manufacturing• Already surmised, additive

manufacturing creates something by adding material to the object.

• Highly efficient and economical.

• No wastage.

Subtractive manufacturing• Subtractive manufacturing

relies upon the removal of material to create something. 

• It’s inefficient and uneconomical.

• Requires extra machinery and results in a huge amount of wastage.

Rapid Prototyping MethodsStereo

Lithography Accuracy (SLA)

Fused Deposition Modeling (FDM)

Selective Laser Sintering (SLS)

Syringe Extrusion

Stereo Lithography Apparatus (SLA)

• The first commercially available 3D printer used the stereo lithography (SLA) method.

• Works by ultraviolet light focused onto the surface of a vat filled with liquid photo curable resin.

• Slices are created, and binded together then extremely high-resolution three dimensional model is lifted out of the vat. 

Fused Deposition Modeling (FDM)• Invented in the late

1980s, by Scott Crump• The object is produced

by extruding a stream of melted thermoplastic material to form layers.

• Less expensive 

Selective Laser Sintering (SLS)

•Powdered materials, such as polystyrene, ceramics, glass, nylon, and metals including steel, titanium, aluminum, and silver are used•When the laser hits the powder, the powder is fused at that point (sintered).• All unsintered powder remains as is, and becomes a support structure for the object. 

Syringe Extrusion

•Almost any material that has a creamy viscosity can be used in 3D printers equipped with syringe extruders. •This includes materials like clay, cement, silicone, and Play-Dough•Certain foods like chocolate, frosting, and cheese can also be printed with these systems. •The syringe may or may not need to be heated, depending on the material; chocolate may need to be kept warm while silicone can be kept at room temperature.

Advantages

Improve accuracy;

Shorten design cycles;

Drive innovation and quality; and

Ease of use;

Improve collaboration among engineering, sales, manufacturing and the executive team

jewelry footwear

Applications:Instantly printing parts and entire products, anywhere in the world

Models of complex architectural drawings are created quickly and inexpensively

Medicine will forever be changed as new bio-printers actually print human tissue for both pharmaceutical testing and eventually entire organs and bones.

The Future of Additive Manufacturing

•Is going to be a Game Changer

•Bridges gap between cyberspace and the physical world

It will change the world as we know it. Before you know it.

References:1. Ian Gibson and David W. Rosen,” Additive Manufacturing

Technologies: Rapid Prototyping to Direct Digital Manufacturing”, Springer Science Business Media, 2010

2. “How 3D Printing Works”, by Z Corporation- http://www.arctron.de/uploads/media/Zcorporation-3DPrinting-Info.pdf