Additive Manufacturing: Materials, Processes, Quantifications and Applications

Jing Zhang, Yeon-Gil Jung

• Publisher: Butterworth-Heinemann
• Year: 2018
• ISBN:
  9780128123270
• Topic: Technology & Engineering
• Subtopic: Materials Science
• Index: Technology & Engineering

Additive Manufacturing: Materials, Processes, Quantifications and Applications is designed to explain the engineering aspects and physical principles of available AM technologies and their most relevant applications. It begins with a review of the recent developments in this technology and then progresses to a discussion of the criteria needed to successfully select an AM technology for the embodiment of a particular design, discussing material compatibility, interfaces issues and strength requirements. The book concludes with a review of the applications in various industries, including bio, energy, aerospace and electronics.

This book will be a must read for those interested in a practical, comprehensive introduction to additive manufacturing, an area with tremendous potential for producing high-value, complex, individually customized parts. As 3D printing technology advances, both in hardware and software, together with reduced materials cost and complexity of creating 3D printed items, these applications are quickly expanding into the mass market.

• Includes a discussion of the historical development and physical principles of current AM technologies
• Exposes readers to the engineering principles for evaluating and quantifying AM technologies
• Explores the uses of Additive Manufacturing in various industries, most notably aerospace, medical, energy and electronics

1

Overview of additive manufacturing process

Michael Molitch-Hou ENGINEERING.com, Mississauga, ON, Canada

Abstract

This chapter provides an overview of AM (additive manufacturing), which is also known as “3D printing.” The chapter at first elaborates on the roots of the technology and then breaks down the various types of processes that fall under the umbrella of AM. Emerging 3D printing technologies are also discussed. A series of homework questions is included for introductory students.

Keywords

additive manufacturing

3D printing

3D printing basics

3D printing overview

laser sintering

metal 3D printing

metal additive manufacturing

Chapter Outline

1. 1 Additive manufacturing technology
2. 2 The birth of AM and vat photopolymerization
3. 3 New 3D printing technologies
   • 3.1 Fused deposition modeling
   • 3.2 Sheet lamination
   • 3.3 Selective laser sintering
   • 3.4 Material jetting
   • 3.5 Binder jetting
4. 4 Metal 3D printing
   • 4.1 Directed energy deposition
   • 4.2 Powder bed fusion
5. 5 Next-generation 3D printing
   • 5.1 Low-cost plastic
   • 5.2 FDM and sheet lamination with composites
   • 5.3 Vat photopolymerization
   • 5.4 Multi Jet Fusion
   • 5.5 New metals
   • 5.6 Hybrid 3D printing
   • 5.7 3D printing electronics
   • 5.8 Bioprinting
   • 5.9 Additive construction
   • 5.10 3D printing food
   • 5.11 3D printing in space
6. 6 Applications
   • 6.1 Visual and functional prototypes
   • 6.2 Tooling
   • 6.3 Example
7. 7 Future applications
   • 7.1 Bigger
   • 7.2 Faster
   • 7.3 Better
   • 7.4 Easier
   • 7.5 Cheaper
   • 7.6 More complex
   • 7.7 The future
8. 8 Homework: what AM is right for a given project?
9. References

1. Additive manufacturing technology

Additive manufacturing (AM) technology, or “3D printing” as it is more commonly known, has taken a hold on our collective imagination, producing wild visions of 3D-printed aircraft and bioprinted organs. Although the technology holds much promise for the future of manufacturing and is already having a big impact on our immediate surroundings, those visions are still far from fully materializing. Regardless of whether the effects occur in the near or long-term, AM is set to fundamentally change the way things are made.

3D printing is a production process by which an object is produced in an additive fashion, layer-by-layer. A digital 3D model, made using computer-aided design (CAD) software or with 3D scanning, is sliced into individual layers, which then supply the toolpath code for a 3D printing machine. Depending on the exact technology, the machine implements a specific process to recreate the model in the physical world from the base slice to the top, until the object is complete.

According to the ISO/ASTM52900-15 standard of AM process categorization, there are seven different types of processes that an AM system might implement to 3D print. This will be discussed in depth in the forthcoming paragraphs and in Chapter 2, which deals with binder jetting, directed energy deposition (DED), material extrusion, material jetting, powder bed fusion, sheet lamination, and vat photopolymerization [1].

• • Binder jetting: A process by which a liquid bonding agent is deposited onto a bed of powder. Can be used with gypsum, sand, glass, metal, and several others.
• • DED: In which metal, as a powder or wire feedstock, is fed in front of an energy source, such as an electron or laser beam, mounted on a multiaxis robotic arm. The material is melted onto a substrate layer-by-layer. Used with metals such as titanium and cobalt-chrome.
• • Material extrusion: A material is deposited from an extruder onto a substrate. Typically, a thermoplastic filament is melted by a heating mechanism and extruded through a hot end. However, the same process can be used with viscous materials such as concrete, clay, organic tissue, or even food.
• • Material jetting: Specialty printheads, such as piezoelectric printheads similar to those found in 2D inkjet printers, spray a liquid material onto a substrate. Most often, this material is a photosensitive plastic resin (also known as a photopolymer) that is then hardened with an ultraviolet (UV) light.
• • Powder bed fusion: This is a process by which an energy source, such as a laser or electron beam, is directed at a bed of powder to heat the individual particles until they melt together. Usually, this technology is associated with metals such as titanium, as well as plastics such as nylon.
• • Sheet lamination: In this process, sheets of material are fused together, with the desired shape etched into each shape. The final object is then removed from the block of bound sheets. This rare 3D printing process is currently most not only often used with paper, but also with metal and plastics.
• • Vat photopolymerization: A vat of photopolymer resin is exposed to an energy source, such as a laser beam or digital light projector, which hardens the material layer-by-layer. This process is usually associated with thermoset plastics.

The technology has been heralded as a breakthrough in manufacturing [2] for a number of reasons, including the ability to automate production, directly fabricate CAD models without the need for expensive tooling, and create complex geometries impossible with other manufacturing methods. While AM has been in existence since the 1980s, it received a newfound resurgence in the media with increased attention by the industry in the early 2010s due the emergence of low-cost, desktop 3D printers.

The hype around desktop 3D printing may have died down, but industry enthusiasm for AM has only continued to increase as a number of larger corporations have invested in the technology. Perhaps most notably in 2016 was that 2D inkjet printer manufacturer HP released its first industrial 3D printing systems, the HP Jet Fusion 3D 4200 and 3200 [3]. In addition, GE Aviation acquired a majority stake in two metal 3D printing companies, Concept Laser an...

Table of contents

• Cover
• Title page
• Table of Contents
• Copyright
• Contributors
• 1: Overview of additive manufacturing process
• 2: Additive manufacturing processes and equipment
• 3: Additive manufacturing of metallic materials
• 4: Additive manufacturing of ceramic components
• 5: Characterization of fused deposition modeling polymeric structures using embedded fiber Bragg grating sensors
• 6: Quantification and certification of additive manufacturing materials and processes
• 7: Multiscale multiphysics modeling of laser powder bed fusion process
• 8: Additively manufactured metals for medical applications
• 9: Additive manufacturing for biofabricated medical device applications
• Index