Andreas Gebhardt

Understanding Additive Manufacturing

Rapid Prototyping - Rapid Tooling - Rapid Manufacturing

ISBN: 978-3-446-42552-1

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http://www.hanser.de/978-3-446-42552-1

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© Carl Hanser Verlag, München

Index

Symbols3D CAD 663D CAD data 313D decoration 963D food printer 1163D graphs 963D grid 1063-dimensional printing (3DP) 473D modeling 23D printing 2, 25, 47, 91, 116

– of foundry sands 873D printing process 37

AABS 135active personalization 123additive digital manufacturing (DM) 2additive layer manufacturing (ALM) 2additive manufacturing (AM) 2, 4, 5

– applications 73 – application sheet 1, 16 – ceramics 138 – complex geometries 104 – composites 138 – definition 1, 4 – design rules 140 – machines 58 – machines, manufacturers 130 – machines, nomenclature 25 – materials 67, 129 – metals 136 – plastics 134 – process 16, 31, 67, 116

– process selection 147 – process chain 66 – properties 147 – standardization 2 – stereolithography 16 – strategies 103

aerodynamic elements/models 97aerosolprinting 56, 57aerospace industry 76AIM 15aluminum 137Anaplastologist 92anisotropic properties 130, 131application 6application workflow 66, 67architecture and landscaping 93art and history of art 83articulated cable clamp 109automotive industries and suppliers 73

Bbionic handling system 112bioplotter 56, 117body scanning 84bonding 35bores 145, 146break out 42bridge tooling 14bronchial tube 105build chamber 35build management 147build platform 35build process 34

Terms not found in the Index may occur in the Glossary

Index162

CCAD data set 4car components

– exterior 75 – interior 73

ceramic micro sintering machines 43ceramics for AM 138cladding 43clamping 143clearance 142clothes 114CoCr-alloys 137colored models 48composite materials 139composites for AM 138computed tomography (CT) 91concept modeling 7conformal cooling 13, 90, 105Connex 38consumer goods 78contour data 5contouring 35cool-down 41copper 137coproducing 118, 126cusing 43customized mass production 117, 118customized product 117cutting 33

Ddata control models 8data formats 67data processing 66delamination 131dental bridge 123design freedom 141Designjet 125desktop manufacturing 3die making 89digital fabrication 2digital light processing 38digital mock-up 2digital product model 5digital to object 141direct manufacturing 2, 11

– example 12direct processes 7direct tooling 2, 11, 12distortion 134distributed customized production 118, 126DLP projectors 33drillings 145drop on powder processes 47

Eelectron beam melting (EBM) 40

– definition 44electron beams 33engineering design rules 140EOS 395 42epithesis 93epoxy resins 135extruders 33extrusion 33, 45

Ffabbers 25, 27, 58, 125fabricators 24, 25, 58fabric-type products 114FDM parts 47FDM post processing 47FDM processes

– plastic materials 46filament 45film hinges 42, 108film joints 142finishing 36flexure hinge 111, 112, 113flexures 142food processing 116formative manufacturing 2foundry and casting technology 85freeform elements 97freeform manufacturing 3front end software 67functional prototyping 7, 8fused deposition modeling (FDM) 45

– example 10fused layer manufacturing 91fused layer modeling 45fusing 43

Index 163

Ggaps 145generative manufacturing 2geodesic data 80, 95graded materials 115green part 67

Hhearing aid shells 122hinges 142hysteresis 143

Iimplant, scull 92indirect manufacturing

– definition 22 – example 22

indirect processes 7 – definition 17

indirect prototyping, definition 17indirect rapid prototyping process 17indirect tooling, definition 20individualization 117, 119infrared heaters 33integrated functionalities 108integrated geometry 106investment casting 88isentropic 130isentropic materials 133isotropic material 115

Jjewelry 119, 120

Kkinematic functions 108knifes 33

Llaminated object manufacturing (LOM),

definition 52laminate manufacturing (LLM) 91laser 33laser fusing 40laser melting 40

– definition 42

laser scanner 35laser sintering 22, 23, 88, 91

– definition 40 – of sand cores 87

laser stereolithography (SL) 34, 91layer-based manufacturing 2layer-based technology, principle 3layer contouring 33layer laminate manufacturing (LLM) 54

– definition 52layer manufacturing 2, 31layer number 5layer oriented manufacturing 2layer thickness 5

– standard 32LLM machines for metal parts 55lost patterns 88lost-wax casting / process 23, 88

Mmagnesium 137makerbot 125Maskles Mesoscale Materials

Deposition (M3D) 56Materials

– plastics 134 – metals 136,137 – ceramics 138 – composits 138

MCOR matrix 54medical application, example 92medical imaging processes 91melting 33, 40melt pool 42meta design 124metal die casting 89metal micro sintering machines 43metal printing 50metals for AM 136micro stereolithography 39mold making 89monochromatic 48multi-material parts 115multi-material processing 56

– of organic materials 116multi-nozzle print heads 33

Index164

Oobjet 37office machines 25, 27, 58organ printing 57on-demand manufacturing 3one-offs 118orientation 142, 143ornaments 96

Ppaper lamination 54partial denture 123particle bonding 33part 3part property management (PPM) 132part property profiles (PPPs) 132, 147PEEK (polyetheretherketones) 135perfectory 38personal fabrication 117, 124personal fabricators (PF) 125personalization 118, 121, 124

– active 121phase changes 141photo-polymerization 33photosensitive 38photosensitive monomers 38physical layer, generation 33pins 145, 146plastic laminate printers 54plastics for AM 134plastic triangle 136plotters 33PMMA 88,136polyamides 42, 134poly-jet matrix 38polymerization 34polymer jetting 37, 38, 91, 115polymer printing 37post-cured 36post-curing oven 36post processing 36powder-binder bonding 47powder-binder process 8powder cake 41practical approach 6printers 25, 58process chain 5product design 103

product development 103prototyper 25prototype tooling 12, 14

– definition 14

Rrapid manufacturing 2, 6

– definition 11 – workflow 69

rapid prototyping 1, 2, 6, 7 – workflow 68

rapid prototyping software 67rapid technology 2rapid tooling 2, 89

– definition 12recoating 36, 41relative fit 141repair software 71roller 41roller-based systems 41room temperature vulcanization (RTV) 18

Ssand casting 86sand (foundry) printing 51scaled concept models 8scull facsimile 91secondary rapid prototyping process 17, 59selective fusing 33selective laser melting (SLM) 132

– definition 42selective laser sintering (SLS)

– definition 40 – example 11

selective mask sintering 40self customization 124shielding gas 40shop floor machines 25, 27, 58show-and-tell models 8silicon rubber molding 18single-nozzle print heads 33sintering 33, 40slicing 32SLM

– machine designs 43 – machines 43 – metals 43

small batch production 118

Index 165

snap-fit 42, 108, 142snap-fit mechanism 110solidica 55solidification 35solid imaging 7solids 31stainless steel 137stair stepping 3, 32, 144standardization 3standard transformation language (STL) 70stereolithography 34

– language 70STL

– data structure 70 – errors 70 – repair 70

STL format 67subtractive manufacturing 2support material 115supports 36

Ttextures 96thermoplastic material 88three dimensional printing 47

– Prometal 50 – Voxeljet 51 – Z-Corporation 48

titanium 137

tolerances 140tool steel 137toy industry 82triangulation 71two-piece hinge 112

Uultrasonic consolidation 55ultrasonics (US) 91undercuts 141UV chamber 36

VVflash, V-flash 58, 123vacuum casting 18vacuum depositing devices 36virtual object 5voxel 3, 116VRML format 67

Wwalls 145wall thickness 146warping 134wax 88wiper-type systems 41

ZZ-printer 48