Chapter 1
Introduction to Additive Manufacturing
Contents
1. Introduction – Manufacturing Processes
2. What is Additive Manufacturing?
2.1 Definition
2.2 History
2.3 Additive Manufacturing vs. Subtractive Manufacturing
3 Benefits of Additive Manufacturing
4. Constraints of Additive Manufacturing
5. Conclusion
6. Questions and Answers
1 . Introduction – Manufacturing Processes
• It is one of the important steps through
which raw material is transferred into final
product.
• Finished Product must meet the tolerances
in order to get accepted and being useful.
• Manufacturing Sequence:
Manufacturing of Car (Source: Tesla’s Factory)
Product Design
Material Specification 1. Conventional Manufacturing → Casting,
Forging, Forming, Welding, etc.
Manufacturing Process 2. Subtractive Manufacturing → Machining
3. Additive Manufacturing
Final Part
What is the manufacturing process?
1. C-Clamp 2. Cast Iron Bearing Housing 3. Cast Iron Bearing Housing
Forging Casting
Casting
4. Aircraft – Aluminum Part 5. Automotive and Aerospace Parts
Thus, we can say
that current
conventional
manufacturing
processes can
produce the part
with the wide
variety of
complexity!!
5-Axis CNC machining
5-Axis CNC machining
Then, why do we need Additive Manufacturing process?
1. Ball with complex lattice
structure 2. Cranial Plate
More Complex Customized Design
4. Aerospace and Defense Parts
Yes, Right! and there
3. Combustion Chamber are lots of reasons for
the need of advanced
manufacturing
processes!
Light
Part Consolidation weighting + You will be able to
Complexity realize as you learn
further about additive
manufacturing.
2 . What is Additive Manufacturing Process
2.1 Definition
The AM is defined as the process which builds the 3D objects from 3D model data
(digital design) by adding the material in layer-wise fashion
• Materials: Metal, Ceramic, Sand, glass, composite, etc.
(a) CAD Model (b) Sliced Model (c) 3D Printed Part
• Schematic of Additive Manufacturing (Source: 3D Hubs)
The principle idea of Additive Manufacturing is producing the any material
by adding layer-upon-layer of the same material.
Synonyms for Additive Manufacturing: 3D Printing, Rapid Prototyping, Direct
Digital Manufacturing, and Freeform Fabrication
2.2 History of Additive Manufacturing
Though AM technologies may seem newly developed technology, it has been started
exploding from 1902.
Following figure shows the growth of Additive Manufacturing
Last two decades are considered as a period of rapid development of Additive
Manufacturing
2.3 Additive Manufacturing vs. Subtractive Manufacturing
Additive Manufacturing Subtractive Manufacturing
• Additive manufacturing • Subtractive manufacturing
adds layers of material. removes material by traditional
processes like milling, drilling,
turning, grinding, etc.
• Fundamental differences between Additive Manufacturing and subtractive manufacturing
Additive Manufacturing Subtractive Manufacturing
Principle of Addition of layers to create the objects Cutting material away from a solid block to
manufacturing create the objects
Processes Selective laser melting (SLM), Selective Milling, turning, grinding, drilling, etc.
involved laser sintering (SLS), Fused deposition
modeling (FDM), etc.
End to Use Simpler – required less supervision Difficult – labor intensive process
Design flexibility Yes – Intricate and hallow objects can be Bit difficult: milling undercuts, intricate
easily built in layers shapes can be difficult
Tolerance ±0.1 mm CNC = ±0.025-.0125 mm
build volume Currently, machine with minimum build Large build volume CNC machines are
(mm3) volume are available (max. 800×400×500 available (2000×800×1000 mm3)
mm3 – Concept laser 2000R)
Suitability Smaller quantity and size (But, it is For manufacturing voluminous objects
changing rapidly!)
Speed Relatively slow process Fast process
Environmentally Minimum waste and clean process More waste after process
friendly
Cost OVERALL AM is fairly cheaper process ; Generally, Prototype: more expensive than
Production: It is expensive AM; Production: It is cheaper
3 . Benefits of Additive Manufacturing
1. Freedom to design and innovate:
• AM technologies are not only just printing the part but
it gives freedom to design and innovate the parts.
• modification and redesign of part occurs without time
and cost penalties unlike traditional manufacturing
processes
• This advantages yields significant rewards
Source: Siemen
2. Reduced the number of components in the assembly
• Thanks to layer-wise technology! This reduces the
number of components.
• The AM process can give the freedom to print
assembly as a one whole part.
Leap Engine Fuel Design Fuel Nozzle (Source: GE)
3. Reduced Lead time:
• This advantage of AM process shortens the supply chain.
• This is because we can create the near net shaped part using AM machines immediately after
preparing the part file.
• reduces the post processing steps and also reduces the labor cost
4. Support Green line manufacturing
• The AM process with the minimum manufacturing steps ensures smaller environmental
footprint.
• This process produces very little waste as compared to that of traditional manufacturing
process
• the AM process is an effective way for light weighting of the part, as much as 60%, which has
reduces the fuel cost and the harmful fuel emission.
5. Rapid Prototyping:
• It reduces time required in the product development.
• Thus, it reduces the time required to the market by accelerating the prototyping.
4 . Constraints of Additive Manufacturing
1. Slow Build Rate:
• The build rate for AM processes are much slower.
• This process is better suited for smaller production scales.
2. Size Limitation:
• The build volume of the printer is varied from printer to printer.
• Part can not be printed larger than build platform.
• This limits the printing of bigger parts and also abundance number small parts.
3. Material Availability:
• Its utilization and versatility are limited to the material availability.
• Special attention is required to develop the material and its data sheet to ensure required
properties.
4. Part Qualification:
• There are some qualities issues associated with the AM process such as part distortions,
shrinkage, and porosity.
• These severely affect the part’s functionality and accuracy.
• Therefore, part’s qualification is the biggest hurdle currently in aerospace and automobile
industries.
• International organization standardization (ISO) and American society for testing and
materials (ASTM) have come together to create the standards.
• This will enable companies to build, qualify and certify the AM parts.
5 . Conclusion
1. Definition:
Additive Manufacturing is the process which builds the 3D objects from 3D model
data (digital design) by adding the material in layer-wise fashion.
2. The material can be metal, plastic, concrete, food, composite, glass, or one day
human tissue.
3. Benefits of Additive Manufacturing: Freedom to design and innovate, part
consolidation, reduced lead time, support green line manufacturing, and rapid
prototyping.
4. Constraints of Additive Manufacturing: Slow build rate, size limitation, material
availability, and part qualification.
6 . Questions and Discussion:
1. What is AM?
2. What are the advantages of AM over conventional route?
3. What are the constraints of AM over conventional route?
4. What can you do to overcome the constraints of AM? Suggest any
three ideas to overcome the constraints.
