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Additive Manufacturing

The document discusses the process of additive manufacturing. It begins by defining additive manufacturing as 3D printing that constructs 3D objects from a digital CAD model in a layer-by-layer fashion. It then describes the typical steps involved, including using CAD software to design a model, pre-processing like simulation and file preparation, printing using different technologies like stereolithography or laser sintering, and post-processing such as removing excess material. Finally, it provides examples of specific additive manufacturing techniques like direct metal laser sintering, electron beam melting, selective heat sintering, selective laser melting, and selective laser sintering.

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Esteban Ero
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141 views9 pages

Additive Manufacturing

The document discusses the process of additive manufacturing. It begins by defining additive manufacturing as 3D printing that constructs 3D objects from a digital CAD model in a layer-by-layer fashion. It then describes the typical steps involved, including using CAD software to design a model, pre-processing like simulation and file preparation, printing using different technologies like stereolithography or laser sintering, and post-processing such as removing excess material. Finally, it provides examples of specific additive manufacturing techniques like direct metal laser sintering, electron beam melting, selective heat sintering, selective laser melting, and selective laser sintering.

Uploaded by

Esteban Ero
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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PROCESSING OF ADDITIVE

MANUFACTURING
WHAT IS ADDITIVE MANUFACTURING?

- 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, typically layer by layer.
WHAT IS THE MACHINE USE FOR ADDITIVE
MANUFACTURING?

- 3D printers use an additive


manufacturing (AM) process where
successive layers of material are
deposited in different shapes to form
the final piece. Design instructions
come from a digital file.
Step 1: Using CAD Software to Design a Model
Some of the top CAD software products for professional use include:
• AutoCAD — AutoCAD is the first and widely used across all industries for
3D design, and known to be extremely versatile in expert hands.
• Creo — a market leader in product design that includes a wide range of
design functionality and the ability to complete dimension calculations
during the modeling process.
• SolidWorks — widely used for industrial object design.
• Step 2: Pre-Processing
- Pre-processing covers a range of steps that must be completed between design
and manufacturing. It covers two primary activities:

1) Simulation Modeling
- Simulation modeling is used to digitally test 3D designs before they are
manufactured.
- Common simulation modeling techniques include Computational Fluid Dynamics
(CFD), Finite Element Analysis (FEA), and Non-Linear Stress Analysis.
2) Preparing Files for 3D printing
- Once a 3D design has been tested and signed off, it’s ready to be prepared for
printing. To do this, a hurdle must be overcome: interoperability.
Step 3: Printing
- Depending on the additive manufacturing technology being used, the ‘printing’
phase can look very different.
- However, other forms of additive manufacturing look quite different.
- Stereolithography (SLA) uses powerful lasers in place of a liquid binder to
cure layers of photopolymer resin. During the build cycle, the building platform
is lowered into a pool of resin, into which the laser traces the pattern of the
layer being printed. Once each layer is cured, the build platform is fractionally
lowered into the resin pool.
- Other common techniques include Selective Laser Sintering (SLS), Metal Laser
Sintering (DMLS), and Electron Beam Melting (EBM).
Step 4: Post-processing
- Post-processing is often the most expensive and time-consuming aspect of
additive manufacturing.

The steps vary depending on the type of additive manufacturing process being
used, but usually fall into three categories:
Build removal — Removing excess material from the object and build platform.
Part separation — Removing the object from the build platform, separating
parts, and removing any support structures used to aid the build process.
Debinding — Soaking objects in a solution to remove any excess binding
material.
TECHNIQUES OF ADDITIVE MANUFACTURING
1. Direct metal laser sintering (DMLS) – is an industrial metal 3D printing
process that builds fully functional metal prototypes and production parts in 7
days or less. A range of metals produce final parts that can be used for end-
use applications.

2. Electron beam melting (EBM) – Electron Beam Melting (EBM) is a 3D


manufacturing technique in which a powdered metal is melted by a high-energy
beam of electrons.
3. Selective heat sintering (SHS) – Selective Heat Sintering is an additive
manufacturing technique to Selective Laser Sintering. However, the two processes should
not be confused. SHS uses a thermal print head to sinter thermoplastic powder, while
Selective Laser Sintering uses a laser to sinter thermoplastic powder.

4. Selective laser melting (SLM) – Selective laser melting (SLM) is a specific 3D


printing technique, which utilizes high power-density laser to fully melt and fuse metallic
powders to produce near net-shape parts with near full density (up to 99.9% relative
density).

5. Selective laser sintering (SLS) – Selective laser sintering is an additive


manufacturing (AM) technology that uses a high-power laser to sinter small particles of
polymer powder into a solid structure based on a 3D model. SLS 3D printing has been
a popular choice for engineers and manufacturers for decades.

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