ADVANCED MANUFACTURING SYSTEMS

(ME-431)
Lecture – 3

Lean Manufacturing,
3D Printing

Course Instructor: Dr. Ammar ul Hassan

Email Id: [email protected]

Department of Mechanical Engineering,

University of Engineering & Technology, Taxila
 INTRODUCTION

• Lean Manufacturing is a production process/ methodology based on an

ideology of maximizing productivity while simultaneously minimizing waste
within a manufacturing operation.

• The lean principle sees waste is anything that doesn’t add value that the
customers are willing to pay for.

• Lean production is a systematic manufacturing method used for

eliminating waste within the manufacturing system.
 INTRODUCTION

• One of the key technology trends in the manufacturing sector at the moment is 3d
printing, or additive manufacturing.

• It has been recognized as a potential industry game changer due to its innovative
nature but also because of its lean characteristics.

• 3d printing has the capacity to reduce waste, save time and thus save money
and in a sector, which is constantly being challenged in those areas, it’s no
wonder it’s garnering a lot of attention.
 INTRODUCTION

• 3D printing or additive manufacturing is

the construction of a three-dimensional object from
a CAD model or a digital 3D model.

• It can be done in a variety of processes in which

material is deposited, joined or solidified
under computer control, with material being added
together (such as plastics, liquids or powder grains
being fused), typically layer by layer.
 INTRODUCTION

• 3D printing or additive manufacturing, creates physical objects

from a geometrical representation by successive addition of materials.

• 3D printing technology can print an object layer by layer deposition of

material directly from a computer aided design (CAD) model.
INTRODUCTION
 3D Printing/ Rapid Prototyping & Rapid Manufacturing

• Companies have used 3D printers in their design process to create prototypes

since the late seventies. Using 3D printers for these purposes is called rapid
prototyping.
History:
History:
General principle:
How it works:
 Materials
• Traditionally, 3D printing focused on polymers (PLA, PP, ABS) for printing,
due to the ease of manufacturing and handling polymeric materials.

• However, the method has rapidly evolved to not only print various
polymers but also metals, ceramics and composites, making 3D printing a
versatile option for manufacturing.

• Layer-by-layer fabrication of three-dimensional physical models is a

modern concept that "stems from the ever-growing CAD industry, more
specifically the solid modeling side of CAD.
 Multi-material 3D printing
• A drawback of many existing 3D printing
technologies is that they only allow one
material to be printed at a time, limiting
many potential applications which
require the integration of different
materials in the same object.

• Multi-material 3D printing solves this

problem (using different extruders) by
allowing objects of complex and
heterogeneous arrangements of
materials to be manufactured using a
single printer.
 Processes and Printers
• The main differences between processes are in the way layers are deposited
to create parts and in the materials that are used.

• Each method has its own advantages and drawbacks, which is why some
companies offer a choice of powder and polymer for the material used to
build the object.

• The main considerations in choosing a machine are generally speed, costs

of the 3D printer, of the printed prototype, choice and cost of the materials,
and color capabilities.

• Printers that work directly with metals are generally expensive. However less
expensive printers can be used to make a mold, which is then used to make
metal parts.
Types of 3D Printers
NOZAL BASED
DEPOSITION SYST.

PRESSURE ASSOCIATED
MICROSYRING
HOT MELT PRINTING

LASER BASED WRITING

SYSTEM

SELECTIVE LASER STEREOLITHO

SINTERING GRAPHY
 1. Nozzle based deposition system
• Nozzle-based deposition systems or Material extrusion: consist on the mixing
of polymers and other solid elements prior to 3D printing.

• The mixture is passed through a nozzle that definitely originates, layer by layer,
the three-dimensional product.

• And fused deposition modeling: The melted material is deposited layer-by-layer

and fused together because the layers are in the molten state as the build platform
moves downwards until the finished product is obtained.
2. LASER BASED WRITING SYSTEM
 LASER BASED WRITING SYSTEM
• Selective Laser Sintering (SLS) expresses one of the latest and advanced technologies for
manufacturing printlets.
• The essential components of a SLS system are a spreading platform, powder bed, and a laser
system (laser and a scanner).
• After the powder is evenly spread over the building platform, the laser draws specific scanning
patterns on the powder surface, which are predesigned depending on the characteristics of the
finished product.
• The powder is sintered by softening or melting of the thermoplastic polymer.
• Subsequently, the powder bed moves down by a height of one-layer thickness while the
reservoir bed moves up to deposit a new powder layer onto the previously sintered layer
followed by laser sintering.
• The process of powder layering and sintering are repeated till desired printlets are formed.
 3. Stereolithography
• Stereolithography is a 3D Printing process which uses a computer-controlled
moving laser beam, pre-programmed using CAM/CAD software.

• Stereolithography is a form of 3D printing technology used for creating models,

prototypes, patterns, and production parts in a layer by layer fashion using
photochemical processes by which light causes chemical monomers and oligomers
to cross-link together to form polymers.

• The 3-D printer's laser "paints" one of the layers, exposing the liquid plastic in the
tank and hardening it. The platform drops down into the tank a fraction of a
millimeter and the laser paints the next layer. This process repeats, layer by layer,
until your model is complete.
3. Stereolithography
 3D Printing materials

METALS RESINS PLASTIC

• Stainless steel • PLA (Polylactic acid or
• High Detail Resins
• Gold polylactide )
• Nickel • Paintable Resin • ABS
• Aluminium (Acrylonitrile Butadiene Styrene)
• Titanium • Transparent Resin • PC (polycarbonate)
• Silver • PVA (Polyvinyl Alcohol)
• Bronze
 • Polyamide
• Alumide

CARBON
POWDERS
FIBER

GRAPHITE & NITINOL

GRAPHENE (Ni-Ti)
 Plastic Filament:
• Plastic is the most common material used in 3d printing because of its
low cost and its easy to use, its also the easiest to melt and can solidify
at low temperature.
• Two common 3D printable plastics are ABS and PLA.
 Acrylonitrile Butadiene
Styrene (ABS)
• ABS is rigid plastic produced from petroleum. It require higher extruder
temperature. A heated printing surface is recommended to prevent wrapping of
the 3D printed material.

• While printing ABS there is usually smell of hot plastic.

 PLA Polyactic acid or
polylactide (PLA)
• Polylactic acid or polylactide (PLA) is a polyester derived from
renewable biomass, typically from fermented plant starch, such as
corn, cassava, sugarcane or sugar beet pulp
Flexible Plastic:
Nylon (Polyamide):
Glow in Dark Plastic:
Wood Filament:
 Copper Filament:
• Copper Filament is printed with a desktop 3D printer. It is similar to
printing with actual copper but much easier. The weight of the material
is three time heavier than regular PLA filament.
• Copper filament will print on both heated and non heated build
platform. The material has no wrapping issue
Powder:
Full color sandstone:
Flexible and Strong Plastic:
Porcelain Ceramic:
Metallic plastic:
Resin:
Metals:
Brass, Bronze, Platinum,
Gold and silver
Steel:
Aluminum:
 Challenges in 3d printing
technology
The technology is still under the developing stage. Hence it undergoes
several challenges such as optimization process, improving performance
of device for versatile use, selections of appropriate substance, etc.

To improve the performance of 3D printed products and to expand the

application range in novel drug delivery systems.

To achieve quality 3D Products, many important parameters need to be

optimized like printing rate, interval time between two printing layer,
distance between the nozzles and the powder layer, etc.
Concept Modeling:
Functional Prototyping:
End Use Parts:
Finishing:
 Advantages

• Advantages
 Rapid production of prototypes.

 Low cost of production.

 No storage cost.

 Quick availability of structures.

 Manufacturing speed.
 Disadvantages

• Disadvantages

Unchecked production of dangerous items

 Limitation of size

 Limitation of raw material

 Cost of printers
Applications:
Applications:
Applications:
Applications:
Applications:
Applications:
Applications:
3D PRINTING PRODUCTS
Thanks