© Bradley Jared, 2023
Principles of Additive Manufacturing
ME 469/569, Fall
Dr. Bradley Jared
Sheet Lamination
1
© Bradley Jared, 2023
Additive Manufacturing
• What is left to explore?
— size / scale / throughput
— energy source
— feedstock form
• powder, wire, liquid, and … sheets
© Bradley Jared, 2023
Sheet Lamination
• ISO/ASTM 52900:2021
— sheet lamination, n: AM process in
which sheets of material are bonded
to form a part
• [Link]
Fig. 9.1 Schematic of laminated object manufacturing process
© Bradley Jared, 2023
source: Fabrisonic
Motivations
color
• Speed & low cost model
• Ease of material sourcing & handling
— dissimilar material constructions heat
• Large parts exchanger
• Applications
— limited industrial use embedded
electronics
• ample R&D performed
— full color paper: visual representations
— wood patterns
— large tooling / dies
• internal cooling channels source: MCor
— embedded components
• automotive, aerospace, electronics
source: Fabrisonic
© Bradley Jared, 2023
Equipment
• Sheet handling
• Registration
— motion stages
— fiducials
— mechanical stops / guides
• Cutting
— mechanical, laser
• Bonding
— dispensing
— heating
— de-bind & sintering Fig. 9.1 Schematic of laminated object manufacturing process
— sonotrode
© Bradley Jared, 2023
302SS prototype (left) & laser Cedeno-Viveros, Int J of Adv Mfg Tech, 2021
micro-spot welds (right)
Layer Bonding
• Clamping
— typically metal
— simple, quick, inexpensive, easy disassembly
• Adhesive
— any material
— low material, equipment & processing costs
— minimal shrinkage, stress or distortion
— rapid fabrication
• Thermal
— metal, polymer, ceramic
— melting, welding, brazing, diffusion bonding, sintering
• Ultrasonic welding
— metal only
ceramic sheet lamination parts
source: Impossible Objects
© Bradley Jared, 2023
Surface Contour Cutting
• Use knife, mill or laser
— typically every ~1-4 layers
• Cut before bonding
— won’t damage prior layers
— easy material removal machining after ultrasonic bonding
— reasonable internal features & channels source: Fabrisonic
— challenges
• layer registration, automating complex geometries,
“island” features, overhangs may require supports
• Cut after bonding
— simple layer registration & automation
— unused material can provide support
— challenges
• internal & high resolution features, excess material
removal, prior layer damage
© Bradley Jared, 2023
Material Feedstock
• Cheap & easily handled
— nontoxic, stable
• Cuttable, bondable material
— paper, polymer, metal, ceramic, composites,
fabric office paper
• Reuse is rare
— challenges removing excess material (ex. metal foil
source: Fabrisonic
lattice, fine features)
— high material waste for sparse parts
• Specifications
— material composition
— size: thickness, width
© Bradley Jared, 2023
Paper full color 3D print from
the Mcor ArkePro
source: Fabbaloo
• 1991: Helisys Inc.
— laminated object manufacturing (LOM)
• 2008: Mcor (Ireland) released 1st paper system
— 2019: assets sold to CleanGreen3D
• Inexpensive
— standard office paper, full color from ink-jetting source: [Link]
• Adhesive bonding
— selectively dispensed, water based
• Final material similar to plywood
— anisotropic mechanical & thermal properties (glue layers)
— z-accuracy limited due to thickness variations & swelling
— finish w/sanding, machining, staining, paint
• coatings required to prevent moisture absorption & wear
• Applications
— realistic models
— wood patterns Dr. Conor MacCormack,
Mcor co-founder
© Bradley Jared, 2023
Cedeno-Viveros, Int J of Adv Mfg Tech, 2021
Metal
• Thermal bonding
— brazing, welding
— Al, steel
302SS prototype (left) & laser
• Diffusion bonding micro-spot welds (right)
— time @ high temperature & pressure
— thick sheets
— tooling / dies / molds
• Al, tool steel
conformal die cooling channels via Innovative Metal Fusion Technology (MFT™)
source: HTS-IC
© Bradley Jared, 2023
Ultrasonic additive
manufacturing (UAM)
• Fabrisonic (originally Solidica, 1999) Fig. 9.7 Ultrasonic
Additive
• 20kHz rotating sonotrode Manufacturing
— solid state, plastic deformation
• 100-200µm foils
— max temp ~ 50% of melting
• ~200°C preheat base plate
— low residual stresses
• Process inputs
— oscillation amplitude (energy), normal force, travel
speed, temperature
• Al, Cu, brass, steel, Ti, Inconel
— layer wise gradient parts
— embedded components: wires, sensors, fibers, etc. Fig. 9.20 UAM functional graded with Cu & Al
© Bradley Jared, 2023
UAM Void Defects
Fig. 9.15 Microstructure of well-bonded Ni–Ni interface
• Based on linear weld density
• Types
Fig. 9.11 Type
— 1: interface, roughness or 1 UAM defect
insufficient energy
— 2: interface, excess energy
damages prior layer
— 3: adjacent strips, inadequate
cross-feed
© Bradley Jared, 2023
carbon fiber parts
Non-Metals source: envisontec
• Polymer
— 1999: Solidimension, PVC sheets
— composite manufacturing
— foam blocks for sculptors
• Tape
— metal, ceramic, composites
• SiC, TiC-Ni, alumina
— form green parts, then de-bind & sinter
• shrinkage: 10-20%
ceramic sheet lamination parts
source: Impossible Objects
paper material © Bradley Jared, 2023
removal
source: 3DBeginners
Printed Parts
• Minimal post-processing
— remove material excess
— sinter / thermal curing
• Properties
— highly anisotropic
Sridharan, Acta Mat,
— out-of-plane (print direction) 2016
• interlayer bond strength UAM Al 6061
— in-plane
• printed sheet material
• typically strongest
© Bradley Jared, 2023
Design Constraints
• Size
machine print
— equipment volume
— sheet size
— Mcor: ~12”, Fabrisonic: ~6’
• Resolution
— limited by material / structure strength under full color paper
machining, bonding & removal source: MCor
— not ideal for sparse structures
• Finish
— machining limits
— layer thickness steps
• Accuracy
— machining limits
— material shrinkage
— part distortion
embedded
• Multi-color / material fiber optic
© Bradley Jared, 2023
Homework: Read Ch. 9
Questions?
16
