WELCOME

S.E. SEM IV

Subject
CAD/CAM
Subject Teacher
Prof Amol Mangrukar
[Ph.D. (Technology), M. Tech (CAD/CAM), B.E. (Mech), PGDGIS(C-DAC, Pune)]
 Module 5

Additive Manufacturing

3/4/2025 2
Prepared By Prof. Amol Mangrulkar,
RGIT, Mumbai
S 5.1 Rapid Prototyping:
– Introduction,
y – Classification of RP Processes,
– Advantages & disadvantages.
l – RP Applications;
•
l •
Design,
Concept Models,

a •
•
Form & fit checking,
Functional testing,
b •
•
CAD data verification,
Rapid Tooling, and
u • Bio Fabrication.

s 5.2 Working Principle, Application, Advantages & disadvantages: of

 Stereolithography Apparatus (SLA)
 Selective Laser Sintering (SLS),
 3D Printing,
 Fused Deposition Modeling (FDM), and
 Laminated Object Manufacturing (LOM)
 5.1.1 Introduction
Preamble: Three Industrial Revolutions
Ind.
Effect Enablers
Rev.
I Mechanization Water wheel and wind mill
(1760-1840) Steam engine, IC engine
Electricity, pneumatics and hydraulics
II Automation (& mass prod.) Hard automation (cam and lever
(1870-1914) operations, clutches and trip dogs 
automats, transfer lines, …)
III Integration (& Custom.) Soft automation (NC, CNC, Robotics
(1950-till date) …), PCs & CAD/CAM/CAE/PLM/ERP
systems
This called Industry-4.0 Network & Internet, 3D scanning & 3DP
Digital (ease of copying, modification and transmission), virtual (high speed; less
expensive and risky), mobile (anywhere, any time), personal (done by self  good
control, confidentiality).
 3D Printing
Challenges conventional design wisdom!
Heralds new paradigms in design!!
Disruptive!!!
 Outline

• Principle • Need for Hybrid and

• 3D Printing Takes Us Multi-Technologies
Closer to Nature! • 3D Printing in Casting
• 3D Printing - A Disruptive • 3D Printing of Sand
Technology of This Era • Conclusions
• Popular 3D Printing
Processes
• Limitations of 3D Printing
• Rapid Manufacturing
• Allied Technologies
6
Principle

7
 Principle
How to make things faster?
The goal is to speed up the design, evaluation and
manufacturing cycles.
Human involvement is the bottleneck to speed. Therefore,
eliminate or at least minimize it through automation.

The two parts of automation are:

i. Automation of process:
(a) Hard automation (automats, SPMs, transfer lines)
(b) Soft automation (CNC machine, robot, AGV, AS&RS, FMS)
ii. Automation of process planning (CAPP):
(a) CAPP for subtractive processes: Failure except axi-sym., prismatic and some 3-axis
(b) CAPP for additive processes: RP

When both are automated, we shall refer it as “Total Automation”

 Principle
Sign Change in Manufacturing: Minus to Plus
- +: Till 1987, manufacturing was
dominated by material subtraction - not
only in machining but also in the formative
processes such as casting and forging.
The sign change in manufacturing with the
advent of Additive Manufacturing by 3D
Systems led to total automation in
converting art-to-part (design-to-
manufacturing or virtual-to-physical). So, it
is faster and hence called Rapid
Prototyping.
It is as easy and simple as 2D printing. So,
CNC machine AM machine
many prefer to call it as 3D Printing.
 Principle
Stay Together (for cows); Divide and Conquer (for lion)

Once upon a time there lived The lion wanted to eat them. A few days passed and the
four cows in the forest. So he went to attack one of cows quarreled among
Every day they used to them. But all the cows joined themselves and started
graze together in a particular together and fought with grazing separately. The lion
spot. They were all friends. him. The lion had to run killed and ate them all one
One day a lion saw the cows away. by one.
10
grazing together.
 Principle
Divide (or slice) and conquer
AM is an
automatic process
of manufacturing
objects (parts,
prototypes, tools
and even
assemblies)
directly from their
CAD models
without any
cutters, tools or
fixtures specific to
the object
11
geometry.
 Principle
Powder-bed multi-jet printing – MIT/ Zcorp/ X1
 Principle
Need for support mechanism

Scaffolding for a water tank

 Principle
Liquid-bed laser printing
 Principle
Jilebi making
 Principle
Fused Deposition Modeling (FDM) - Stratasys
 Principle
Various names of 3D Printing

Rapid Prototyping (RP)

Stereo-Lithography (SL)

3D Printing (3DP) (What can it do?)

Additive Manufacturing (AM) (How does it do?)

Layered Manufacturing (LM) (a subset of AM)

Solid Freeform Fabrication

Direct Digital Mfg … 17

 Principle
Analogy with printing
 Principle
Analogy with printing …

Totally automated 2D printing Totally automated 3D printing

(Lithography) (Stereo-lithography)

AM revolutionized the way products are designed and manufactured

today. It is an effective tool to compress product development time
and hence gives an edge over the competitors.
3D Printing Takes Us Closer to Nature!

20
 3D Printing Takes Us Closer to Nature!
Characteristics of Nature: Rotation?

Nothing rotates in nature (except at the extremes of celestial and

atomic scales!)

Is wheel really the greatest

invention of mankind? Could
have been something else? Our
imaginations are blocked by the
symmetry of wheel!
21
 3D Printing Takes Us Closer to Nature!
Characteristics of Nature: Rotation? …

Mathematically simpler horizontal flat surface “z=0” is more

expensive to produce than a cylindrical surface which is
mathematically more complex “x2 + y2 – r2 = 0”

The
cheapest
machine is
lathe, then
shaper,
milling
machine
etc.
22
 3D Printing Takes Us Closer to Nature!
Characteristics of Nature: Flatness?
Natural surfaces are rarely flat (2D) or Engineering
graphics –
symmetric; all are 3D and organic.
Effort to
capture 3D on
2D!

Is writing – expressing
the sense of sound
through symbols, the
simplest form of sense
of vision, another worst
invention of mankind?
It has been a major
source of human 23
conflict!
 3D Printing Takes Us Closer to Nature!
Characteristics of Nature: Homogeneity?

• Nothing in nature is homogeneous – different densities and

materials at different places – with appropriate purposes

24
 3D Printing Takes Us Closer to Nature!
Characteristics of Nature: Assembly?

• Nature does not make individual parts and assemble

25
 3D Printing Takes Us Closer to Nature!
Characteristics of Nature: Assembly?

• Nature’s manufacturing has no wastage!

26
3D Printing Takes Us Closer to Nature!
Characteristics of Nature: Assembly?

All these characteristics are because,

Nature never does subtractive manufacturing!
Subtraction means destruction!!
Nature does always Additive Manufacturing!!!

Since 3D printing also uses Additive Manufacturing, it

takes us closer to the Nature.

27
 3D Printing Takes Us Closer to Nature!
3D Printing takes us closer to the Nature
3D printing, like Nature, produces through material addition; hence,
• Geometric complexity: Like nature, it realizes all geometries with
the same ease.
• Matrix complexity: Nature does not care for the matrix complexity.
Most natural objects are inhomogeneous in the desired way to
achieve optimal performance. Same with 3D printing.
• Variety of materials: Natural objects constitute a variety of
materials to have the desired properties of strength and
rigidity/flexibility as required. Same with 3D printing.
• Direct assemblies: Most natural objects are direct assemblies.
• No wastage: There is no material wastage in the form of chips,
28
swarfs or fumes. Same with 3D printing.
 3D Printing –
A Disruptive Technology of This Era!

29
 3D Printing – A Disruptive Technology
Other disruptive technologies
Disruptive technologies defeat the purpose for which they are
introduced; but we do not regret the disruption, because they are not
destruction; because they compensate for the loss in unimaginable
ways!
• CAD: It has made Engineering Drawing redundant for which it was
introduced.
• Internet: It ruined the business of the malls and the agents through
online transactions but made it cheaper and better for us.
• Smart phones: Does much more than talking.
• 3D scanning:
• 3D Printing:
30
 3D Printing – A Disruptive Technology
State-of-the-arts
Total automation is the foremost advantage of 3D printing.
Objects of any kind of geometric (direct assemblies, non-linear ducts,
custom, difficult, optimal light/lattice structures) or material (any variety
– poly/ metal/ ceramic, non-equilibrium, gradient – mono/ composite/
gradient, porous/lattice, soft/hard) complexity can be produced.
DFM (compromise) vs DFAM (design freedom makes it disruptive).

Geometric (boundary)
Material (interior)

31
 3D Printing – A Disruptive Technology
Geometric complexity: Direct assemblies

Courtesy: EoS, Germany

Thin walled turbine combustion

chamber, produced on EOSINT M 270,
material EOS Nickel Alloy IN 718.
32
Courtesy: Materialise Solutions, U.K.
Courtesy: Stratasys, USA
 3D Printing – A Disruptive Technology
Geometric complexity: Non-linear ducts (CCC)

Drilled straight cooling duct Conformal cooling duct

Benefits:
• Cycle time reduction
• Less distortion
• Good matrix integrity
3D Printing – A Disruptive Technology
Geometric complexity: Non-linear ducts (CCC)
 3D Printing – A Disruptive Technology
Geometric complexity: Non-linear ducts (CCC)

Hybrid approach: Modify the machined die to incorporate CCC.

Good example of DFAM too!

3D Printing – A Disruptive Technology
Geometric complexity: Non-linear ducts (CCC)

36
3D Printing – A Disruptive Technology
Geometric complexity: Non-linear ducts (fuel inj.)

A 3D printed fuel injection nozzle of

GE’s LEAP jet engine:
• The nozzles are five times more
durable.
• One part rather than 20 individual
parts.

37
Courtesy: CFM International
3D Printing – A Disruptive Technology
Geometric complexity: Affordable customization

38
Mass customization – redefined!
3D Printing – A Disruptive Technology
Geometric complexity: Difficult or complex shapes

39
 3D Printing – A Disruptive Technology
Geometric complexity: Optimized light/lattice structure
Shape or topology
optimization: Popular
FEA packages now-a-
days have module for
iterating the shape to
remove non-load
bearing matter!
Eg.: Altair’s Optistruct

40
 3D Printing – A Disruptive Technology
Geometric complexity: Optimized light/lattice structure
3D printed electric
motorbike:
• 35 kg
• 80 kmph
• 60km range
• Al body looking cheese!
• 50,000 euro!

[Courtesy: Airbus (Tom

Enders, CEO) +
APWorks (Joachim
Zettler]
41
 3D Printing – A Disruptive Technology
Geometric complexity: Optimized light/lattice structure

Knee cap

Netfabb’s Selective
Space Structures
(3S) Software
Face implant

42
 3D Printing – A Disruptive Technology
Geometric complexity: Optimized light/lattice structure

Plastic plaster:
Scratching during
itching; IR therapy for
fast recovery; removal
when required

OsteoAnchor architecture applied to a short

hip stem design (left); X-ray of device
implanted in cadaver femur (right):
43
Differential finish on the same object
 3D Printing – A Disruptive Technology
Geometric complexity: Optimized light/lattice structure

44
 3D Printing – A Disruptive Technology
Material complexity: Monolithic poly/metals/ceramics
S’L’S (EoS, SLM,
Renishaw, ComceptLaser,
3DSystems, …)
S’EB’S (Arcam)
Note: Binder-based multi-
jet technologies are not
good.

Binder-based multi-jet
technologies (ExOne,
Voxel) are more suitable
here than SLS.

45
 3D Printing – A Disruptive Technology
Material complexity: Gradient and/or non-equilibrium Matrix

Courtesy: ZCorp, USA

46

Courtesy: Bajaj Auto, Pune Courtesy: Optomec, USA

 3D Printing – A Disruptive Technology
State-of-the-arts
Total automation is the foremost advantage of 3D printing.
Objects of any kind of geometric (direct assemblies, non-linear ducts,
custom, difficult, optimal light/lattice structures) or material (any variety
– poly/ metal/ ceramic, non-equilibrium, gradient – mono/ composite/
gradient, porous/lattice, soft/hard) complexity can be produced.
DFM (compromise) vs DFAM (design freedom makes it disruptive).

Geometric (boundary)
Material (interior)
Anything that can be modelled, can be printed!

47
 3D Printing – A Disruptive Technology
Design for Additive Manufacturing (DFAM)
• Optimize the design by using the elegant geometric and
matrix capabilities
Geometric/Matrix Capability Benefits
Direct assemblies Total automation  quick time-to-market
Non-linear ducts Weight reduction  Cost saving &
Custom geometries Performance improvement
Light structures Scaffolding
Lattice structures Minimum post-processing (elimination of
assembly, less finishing effort in castings)
Complex geometries
Differential finish
Material variety
Gradient objects
48
Non-equilibrium matrix
 3D Printing – A Disruptive Technology
Fears/ Concerns: Will AM Kill Machining Technology?

Hype is required to promote the new technologies such as 3D

Printing, 3D scanning, Internet etc. But such a hype shall not cause
unfounded fears and anxieties. Because they will become
counterproductive for their acceptance. Similar past hypes/fears are:
• When robots were introduced, the operators were worried about their jobs.
• When PCs were introduced for typing, clerical staff suffered the same anxiety.
• When color printers were launched, people were worried about counterfeit
currencies and forged documents.
• When someone demonstrated making a pistol, security agencies worried about
the introduction of 3D Printing.
• The original term NMRI was reduced to MRI as the word ‘nuclear’ made people
uncomfortable.
All these fears eventually were proven wrong!
 3D Printing – A Disruptive Technology
Fears/ Concerns: Will AM Kill Machining Technology?

No new technology such as 3D Printing, will not replace the existing

ones but will only complement. Because
• There is no omni-potent process except God. Unfortunately, He
cannot be hired.
• 3D printing is just another manufacturing process just like CNC or
robotics with a higher level of automation achieved through some
compeomises.
• All processes and technologies differ among themselves in terms
of capabilities, quality, cost and speed. So, every process has its
place. They do not conflict but complement.
But there may be shock initially which can be overcome with foresight
and training.
Geometric Input to AM

51
 Geometric Input to AM
STL format

The greatness of
this man lies in his
simplicity!
Gandhi and
Ganapathy don’t
complain!!
Coarse resolution Fine resolution
 Geometric Input to AM
STL format …
solid AutoCAD
facet normal 0.0000000e+000 0.0000000e+000 1.0000000e+000
outer loop
vertex 1.0000000e+001 0.0000000e+000 1.0000000e+001
vertex 1.0000000e+001 1.0000000e+001 1.0000000e+001
vertex 0.0000000e+000 1.0000000e+001 1.0000000e+001
endloop
endfacet
…
…
…
facet normal 1.0000000e+000 0.0000000e+000 0.0000000e+000
outer loop
vertex 1.0000000e+001 0.0000000e+000 0.0000000e+000
vertex 1.0000000e+001 1.0000000e+001 0.0000000e+000
vertex 1.0000000e+001 1.0000000e+001 1.0000000e+001
endloop
endfacet
endsolid AutoCAD
 Geometric Input to AM
STL format …
1. ASCII format
- Human readable
- Large file size

2. Binary format
- Only machine readable
- Small file size. As small as a 5th in size.

The MMX format of Materialise compresses ASCII STL file to a

100th. It eliminates redundant storage. It also makes use of the
compression techniques.
 Geometric Input to AM
STL format …
Advantages: Limitations:
• Simplest • This is an inexact representation.
possible format • For the same precision, the file size is larger
to represent a
than its exact form.
3D geometry –
so simple that it • This is an unordered set of faces. Topology is
ensures 100% not explicitly available. It has to be extracted.
portability of • The same point is repeated several times in
data among the file. This not only increases the file size but
CAD systems. also leads to defects such as gaps, overlaps
• Compatibility etc. as the same point may be interpreted as
with other different points at the floating point precision.
systems • Normal is also a redundant storage.
Popular 3D Printing Processes

56
 Popular AM processes

Powder-bed tech.; No laser, just a liquid binder, hence cheap, all materials.
3DP ZCorp: Starch; FGM (color); SoliGen: Ceramic; FGM; ProMetal: Metal; FGM

Powder-bed tech.; Laser, hence costly but faster and accurate, all materials.
SLS 3D Systems: Single machine; EoS: 3 different machines; Many clones

Liquid-bed tech.; Laser, hence costly but faster and accurate, photopolymer.
SLA 3D Systems; Many clones; other photo-polmer sys’: SGC, Envisiontec, Objet

Extrusion of thermoplastics; No laser, hence cheap but slow and less accurate.
FDM Stratasys (www.stratasys.com) <video: Deposition-FDM-Stratasys-Process>

Joining profiled laminates; not sophisticated laser, hence cheap. Fast.

LOM Cubic (www.cubic.com) <videos>; Kira, SolidDimension, Solidica <video>
 Popular AM processes
Videos

Powder Bed-Binder-3DP-ZCorp-Starch-Monochrome & Color

3DP Powder Bed-Binder-ExOne-Sand-Actual

Powder Bed-Laser-SLS-EoS-Sand-in ACTech

SLS Powder Bed-Laser-SLS-EoS-Metal

Liquid Bed-SLA-Mommoth-Materialise
SLA

Deposition-FDM-Stratasys
FDM Deposition-LENS-Metal; HLM of IIT-B

Laminated Manufacturing-LOM
LOM
 Popular AM processes
Classification: Feedstock form: Solid-powder
Technology Vendors/ Products
Powder-based Processes: • Multi-jet raster type: Z-Corp, USA for
3D Printing (developed by polymers
MIT, USA)
• Multi-jet raster type: ExOne, USA for
sand (and metal too)
• Multi-jet raster type: Hoeganos,
Sweden for metals
Powder-based Processes: • Single-laser vector type: DMLS from
Selective Laser Sintering/ EoS for polymers, metal and sand, ...
Selective EB Sintering
• Single-EB vector type: Arcam,
(developed by UTA, USA) Sweden
 Popular AM processes
Classification: Feedstock form: Solid-others (sheet, wire, granule…)

Technology Vendors/ Products

Laminated Object Helisys (Cube), Kira, SolidDimension
Manufacturing
Fused Deposition Modeling Stratasys, Reprep, Clones
Fused Deposition Modeling Sander’s Model Maker II
5-axis FDM using extruder Arburg
screw IIT Bombay
 Popular AM processes
Classification: Feedstock form: Liquid (photopolymer)
Technology Vendors/ Products
Liquid-based Processes: • Stereo-lithography Apparatus (SLA)
using photo-polymer from 3D Systems, USA
• Solid Ground Curing (SGC) or Photo-
masking from Cubital, Israel
• Multi-jet modeling from Objet, Israel
merged with Stratasys
• Perfactory from EnvisionTech,
RapidShape from Schultheiss
 Popular AM processes
Classification: Feedstock form: Liquid (wax, water …)
Technology Vendors/ Products
Liquid-based Processes: • Multi-jet raster type: ProJet of 3D
using wax Systems, USA
• Single-jet vector type: SolidScape,
USA (part of Stratasys now)
Liquid-based Processes: • Single-jet vector type: M.C. Leu of
using water Missouri University of Science and
Technology (not commercialized)
• Multi-jet raster type: ice prototyping,
IIT Bombay (under development)
 Popular AM processes
Classification: Feedstock form: Gas (not yet!)
Technology Vendors/ Products
Sand 3D Printer (Sand + IIT Bombay (but we have given up due
Solidum Silicate bed to its poor recyclability and due to the
printed with CO2) availability of better routes for sand
molds.
 Popular of AM processes
Classification: International (not satisfactory to me)
Sl.
Approach Remarks
No.
1. Binder jetting An additive manufacturing process in
(3DP – Zcorp, ExOne, which a liquid bonding agent is
Voxel, Hoeganos …) selectively deposited to join powder
materials (both single and multi-jets).
2. Material jetting An additive manufacturing process in
(Objet, 3DS’s multijet which droplets of build material are
…) selectively deposited (both single and
multi-jets).
3. Material extrusion An additive manufacturing process in
(FDM …) which material is selectively dispensed
through a nozzle or orifice.
 Popular of AM processes
Classification: International (not satisfactory to me) …
Sl.
Approach Remarks
No.
4. Powder bed fusion An additive manufacturing process in
(SLS, Arcam’s EBM which thermal energy selectively fuses
or S’EB’S …) regions of a powder bed.
5. Directed energy An additive manufacturing process in
deposition which focused thermal energy is used
(LENS, POM …) to fuse materials by melting as they
are being deposited.
 Popular of AM processes
Classification: International (not satisfactory to me) …
Sl.
Approach Remarks
No.
6. Sheet lamination An additive manufacturing process in
(LOM …) which sheets of material are bonded to
form an object.
7. Photo-polymerization An additive manufacturing process in
(SLA …) which liquid photopolymer in a vat is
selectively cured by light-activated
polymerization.
 Popular of AM processes
3 Considerations in the selection of AM process

1 2 3
Material Min. layer thickness Support mechanism
Quality requirement Quality requirement Quality requirement
influencing strength, influencing geometry influencing surface
weight, life, (accuracy and surface finish of undercut
transparency etc. finish) regions

Solid-powder: High material variety; simple support mech. Requirement

Solid-sheets: High material variety; Fast; ease of handling;
material wastage influencing
Solid-wire: Ease of feeding; high material variety and (a) additional
utilization material, (b) time, (c)
Liquid: Excellent accuracy; transparency; Complex support
mech. cost, (d) feasibility of
Gas: Not yet but why not! manufacture
Benefits & Applications
 Benefits & Applications
Unique and significant capabilities
Total automation is the foremost advantage of 3D printing.
Objects of any kind of geometric (direct assemblies, conformal,
custom, complex) or material (any variety – poly/metal/ceramic, non-
equilibrium, gradient – mono/composite/gradient, porous/lattice,
soft/hard) complexity can be produced.
DFM (compromise) vs DFAM (design freedom makes it disruptive).
Geometric (boundary)

Material (interior)
 Benefits & Applications
Various applications
• Concept models for better • RP models can be sent along with the
visualization (high bandwidth inquiries; RP models can be submitted
communication tool) along with the quotations.
• Models to check the aesthetic appeal; • Medical applications in conjunction
also for market survey. with VR, AR & RE.
• Models for form, fit and functional • RP also has its applications in
tests micro/nano-applications.
– Models for stress analysis using • RP is emerging into Rapid
photo-elasticity Manufacturing.
– Models for wind tunnel tests
– Models for design review • Essentially RP cuts down product
development time and RT cuts down
• Assemblies can be made without productionizing time. With an
joints. It can make parts impossible by integrated approach, RP, RT & RM
other manufacturing methods. can shorten time to market.
 Benefits & Applications
AM for Common Public (June 2013!)
 Benefits & Applications
Photo-elasticity models, working prototypes, patterns

Concept model Transparent models for photo-elasticity studies

Material translation through Investment Casting Fully functional prototypes

 Benefits & Applications
Many design iterations within limited time

• Design iterations improve “quality of

design”. But they also consume resources.
• Never evaluate an idea at the time of
brainstorming.
•Never fall in love with your own ideas; this
will block newer ideas
 Benefits & Applications
Quad-Copter: A Micro-Aerial Vehicle

Commercial Quad-copter First version (did not fly) First flying version
App-MAV-5-Outdoor Free Flight-20071019

Several iterations Blade used in flight

 Benefits & Applications
High Bandwidth Communication Tool: Gas Turbine
• Rs. 19,80,000
(30,000 Euro )

• 3 Weeks (Time-
bound delivery
through extensive
outsourcing)

• High bandwidth
communication
tools

•1:1 working model

(1.1m long)
V08-GTRE Engine
 Benefits & Applications
Tooling in Blisk (Bladed Disk) Machining

• High aspect ratio

(0.2 – 0.9mm thick, 70mm
overhang)
• Freeform shape
• Ti (presently Al)
 Benefits & Applications
Tooling in Blisk (Bladed Disk) Machining
 Benefits & Applications
Tooling in Blisk (Bladed Disk) Machining

Team: Yashwant & Rony

 Benefits & Applications
Energy Relay: ASME intern’l student competition
• Energy Relay: Design four toy • Autonomous trigger to sustain
cars using four different energy the relay.
sources. • In India, they won with a record
• Max vehicle size : 100 x 100 x of 5.9s.
200. Each will travel a min of • Next event: April 2012 in Dubai
3m and totally together cover a
min. of 12m. Courtesy: Mayank Porwal et al.

Compressed Air Spring Energy Electrostatic energy Electrochemical Energy

App-Energy Relay
 Benefits & Applications
Electric CAR: SAE intern’l student competition

Courtesy: Urmil Shah et al.

SLS models built by Imaginarium for CNC machined components
fitment check. FDM also is suitable. assembled with brake drum.
 Benefits & Applications
Wind Tunnel Models

A new concept of vertical wind mill [courtesy: Prof. S.V. Prabhu, Mech.]
 Benefits & Applications
Wind Tunnel Models

Straight blade Straight Parabolic Straight Parabolic

with T106 swept blade swept leaned leaned
profile blade blade blade

Turbine blade study [courtesy: Prof. Roy, Aerospace]

 Benefits & Applications
Wind Tunnel Models

Turbine blade study [courtesy: Prof. Roy, Aerospace]

Benefits & Applications
Forming Die

[courtesy: Prof. M.V.

Rane, Mech.]
 Benefits & Applications
Medical
CAD/CAM tools such as Reverse Engineering, Virtual and Augmented
Reality and Rapid Manufacturing have wonderful medical applications.

1. Models 2. Prosthetics

3. Implants 4. Surgical devices/ instruments

Limitation of AM
 Limitation of AM
Challenges in AM: Poor external quality
(i) Poor surface finish (ii) Irregularities created during
due to stair-step error support removal

CAD model

When surface finish is very poor,

AM part tolerance cannot be better than that!
 Limitation of AM
Challenges in AM: Poor internal quality
- Each RP process has a - All RP materials are
limited material proprietary
composition, that too, in - Due to open loop (absence
narrow band of properties of human)
FDM – Polymers - Commercial reasons:
(thermoplastics) Exorbitantly priced (40-60%
SLA – Photo-polymer of cost is material)
SLS/3DP – Good variety from - Limited shelf life
polymer to metal but one
machine for each.
LOM – Paper

- Inherently anisotropic
 Limitation of AM
Challenges in AM: Slow

MCP Realizer
at LERMPS-
UTBM, Belfort

Matl: Ti64; Size: 83 x 68 x 131; layer thk. = 0.040 (1700); Time: 60 hrs.

Stand in front of a CNC machine for 5 min (when it is working!) and

then in from of a AM machine for 5 min. You will find out which is fast!
That is why we do not call it RP any more!!
 Limitation of AM
Challenges in AM: Linearity of cost & time

All AM materials are AM has linearity of cost

proprietary and (& time) with quantity.
exorbitantly priced (40-
60%)
Exorbitantly priced RP
equipment in order to
recover IP fast.
Indirect Processes
 Limitation of AM
Challenges in AM: Summary

Quality i. Exterior or surface - Surface finish

- Accuracy
ii. Interior or matrix - Composition
- Limited range of each process
- Proprietary
- Homogeneity (inherent anisotropy, porosity
& residual stresses)
Cost Linear!
Time Time to build Not rapid enough!
- Number of layers
- Sacrificial support
Life Low life due to
- Poor quality
- Degeneration over time
Rapid Manufacturing (RM)
 Rapid Manufacturing (RM)
Definition
The usefulness of AM is amplified manifold through appropriate pre/in-
situ/post-build processes to overcome their limitations.
Pre-build processes In-situ build processes Post-build processes
Reverse Engineering Embedding PCB, inserts Improving surface quality
etc. (polishing, machining)
Model processing: Data
reduction, splitting large Cold working after every Improving interior quality
pieces along with joints layer (Thermal and/or pressure
for gluing, editing treatments)
models, repairing Machining in-between a
models, lattice structure certain number of layers Multiple pieces and/or of
desired material through
Analysis and indirect routes (vacuum
optimization (OptiLOM) casting, metal casting)
Additive Manufacturing + Allied Technologies = Rapid Manufacturing
 Rapid Manufacturing (RM)
RM = AM + Allied Technologies
Metallic
RM

Direct Matl. Geom. Indirect

Routes Routes
SRM Best Best
LM Ok Ok Rapid
6 Casting
HLM Ok Best
Subtractive Additive
RC Best Ok

CNC Laminated Powder-bed Deposition Without With

Machining Manufacturing Technologies Technologies 4 Patterns Patterns

1 2 3
Non-
Bonding Sintering Fusion Additive Subtractive Consumable
Consumable

Laser EB Arc Unlike the layered mfg approach of RP, RM

would require multi-faceted and hybrid
approaches to meet the varied needs of
5 Hybrid material, quality, quantity, cost etc.
 Rapid Manufacturing (RM)
Various Metal 3D Printing Routes

Metallic
RM

Direct Indirect Routes

Routes (Rapid Casting)

Without With
Powder-bed Cladding
Patterns Patterns

Laminated Non-
Consumable
Manufacturing Consumable
 Rapid Manufacturing
Polymeric objects (Indirect)

Rapid Manufacturing
Metallic and ceramic objects (Direct)

Rapid Manufacturing
Met. and cer. objects (Indirect)  Rapid Casting
Allied Technologies (Pre-Build)
Allied Technologies (Pre/In-situ/Post-Build)
Lattice structure

OsteoAnchor architecture applied to a short

Netfabb’s Selective Space hip stem design (left); X-ray of device
Structures (3S) Software implanted in cadaver femur (right)
Allied Technologies (Pre/In-situ/Post-Build)
Lattice structure …

An aluminum sandwich panel heat exchanger

with a pyramidal lattice core
Allied Technologies (In-situ-Build)
Allied Technologies (Pre/In-situ/Post-Build)
In-situ Preheating (using induction heating)
Allied Technologies (Pre/In-situ/Post-Build)
In-situ stress relieving (thro’ pneumatic peening)
Allied Technologies (Post-Build)
Allied Technologies (Pre/In-situ/Post-Build)
Exterior improvements: Liquid polishing
Micro-Machining of
BestinClass, Swiss
Allied Technologies (Pre/In-situ/Post-Build)
Interior improvements: Hot Iso-static Pressing (HIP)
Powder-based RP (laser/EB
sintering or bonding) is not
strictly PM as compacting is
missing. Powder-based
metallic AM processes
invariably have some micro-
porosities which reduce their
fatigue life required in
aerospace. HIP makes them
as strong as machined or
forged components.
HIP combines the geometric
complexity of Casting with the
matrix quality of Forging!
Allied Technologies (Pre/In-situ/Post-Build)
Indirect Processes: Investment Casting (QuickCast)

3D Systems’ SLA mchine

produces quasi-hollow
patterns. Note that:
• the honeycomb structure is
achieved using QuickCast
build style and no special
geometric pre-processing is
required.
• Hollowness is not for saving
material or speed but to
avoid shell cracking. Courtesy: Mercedes-Benz
QuickCast uses flask
investment casting.

Of late, SLS’s dense

polystyrene patterns are
replacing this. Knee implant
Courtesy: Bajaj Auto,
India
Allied Technologies (Pre/In-situ/Post-Build)
Indirect Processes: Investment Casting

Magnesium Seal
housing of Kaveri
engine (GTRE,
Bangalore) made by
Aerocast, France
Conclusions
 Conclusions
• “Divide & conquer” approach of Additive Manufacturing (AM) led to
total automation. This revolutionized the way products are
designed and manufactured today.

• The same “divide & conquer” approach is responsible for the

pathetic quality, short life, long production time and high cost.
These bottlenecks can be overcome by adopting appropriate allied
technologies which are the pre-/in-situ/post-build processes. These
together are known as Rapid Manufacturing (RM).

• HYBRID technologies are more relevant. They may be [addition,

subtraction], [bonding, fusing, melting], [Arc, Laser, EB], [2.5 ax, 3-
ax, 5-ax], [Direct, Indirect] … RM exists for any situation. So (a)
their appropriate selection and (b) Design for RM are essential for
efficient product development.
 Conclusions
Three levels of RM processes

Characteristics L1 L2 L3
Name 3D Printing RM for polymers RM for polymers,
metals and ceramics
Price < Rs. 10 lacs < Rs. 1 cr Even greater
($ 20,000) ($ 200,000)
Materials Limited to one A variety of polymers A variety of polymers,
polymer ceramics and metals
Technologies Only AM AM and Indirect (Vac. AM & indirect (Rapid
Casting etc.) Casting, HIP etc.)
Purpose Only visualization Functional; need not Functional; need not
be limited to prototype be limited to prototype
Location In-house; preferably The same organization will require more than
in every design office one technology. Load will not be enough to
like a 2D printer. justify in-house facilities. So outsourcing is
preferred except for one or two essential ones.
 Conclusions
State-of-the-arts
Total automation is the foremost advantage of 3D printing.
Objects of any kind of geometric (direct assemblies, conformal,
custom, complex) or material (any variety – poly/metal/ceramic, non-
equilibrium, gradient – mono/composite/gradient, porous/lattice,
soft/hard) complexity can be produced.
DFM (compromise) vs DFAM (design freedom makes it disruptive).
Geometric (boundary)

Material (interior)
If you can model anything, I can print it!
 Conclusions
Disclaimer

No new technology will replace the existing ones but will

only complement. Because
(a) God is the only technology/ operator that is omni-potent
(b) He is not available for hire!
 Way Ahead

• While the West looked at robots as humanoids, the Japanese

looked at them as machines and applied them for assemblies and
work handling. In the same way, look at 3D printing as just one
more manufacturing process.
• 3D Printing will not do great things in isolation. But in conjunction
with the allied technologies, it does wonders. FEA and HIP to
name a few.
• It will not be effective to produce a casting or a machined part or a
forging or a sheet metal part through 3D printing. You will have to
redesign them to exploit its unique capabilities and bypass its
limitations. This area is called Design for Additive Manufacturing
(DFAM).
 Way Ahead
Academia and industry should join hands
The qualifications of academia and industry are same. Then, why is
the disconnect? Perception: Academicians have no sense of time and
highly unorganized; Industry is under pressure and hence is unable to
focus on creativity and innovation, afraid of taking risks, complacent
often. Solution: Trust each other, appreciate limitations, come out of
comfort zones and walk the extra mile to come closer!
• Industrial visits and Internships: Students become more relevant at graduation
• Student projects at B.Tech., M.Tech, and Ph.D. levels: The projects becomes
more applied rather than fictitious.
• Sponsored research: fully/partially (20:80); in cash/kind; at least validate and
comment!
• Consulting projects: to solve your specific projects that lead to joint IP,
products/processes.
• Mutual mobility: Sabbatical/adjunct; examiners; joint publications
 Way Ahead
Let Us Come Closer! Join Hands!!

Courtesy: B.Ravi, OrthoCAD Lab, IIT Bombay

Don’t compromise! Feel free to complicate geometry and material to
achieve the optimal design!!
 Way Ahead
Two directions
• Direct metal printing when size is less than 250mm. Cladding
method for larger parts. Rapid Casting for even larger parts
including sand 3D printing.

• The power of 3D printing is amplified through pre-/in-situ/post-build

processes. These together are known as Rapid Manufacturing
(RM). HIP is one of them.

• Two pronged approach:

i. Investing in commercially available technologies to explore

innovative applications in product development.

ii.Development of indigenous 3D printers for various materials.

 Way Ahead
Significant application verticals for metals

High end applications Simple applications

(Tough but high margins!) (low hanging fruits!)
Aerospace (Ti, Ni, Al, SS) Automotive and other ground
applications (Fe, Al)
• Two wheeler parts
• Al molds for rubber parts like
tyres etc.
• Injection molds with
conformal cooling channels
• Stream turbine parts
Medicine (Ti, SS, Cr-Co-Mo) Tooling (Fe, Al)
HIP Rapid Casting for machine tools:
Sand mold printing
 Way Ahead
Promotion of technology
• About 20 CoEs through the country. These may be part of popular
academic institutions with adequate freedom and very high
industrial focus. Hand holding and joint problem solving as against
service in ‘clusters’.
• We are in touch with DHI and other funding agencies.
Thank You!