NEED FOR ADDITIVE MANUFACTURING

To reduce lead-time in Product Development

To Produce Parts with Complex geometry

Freedom for Designer

Development of New Materials and Process

A drawing is worth of 1000 Words

A Prototype is worth of 1000 Drawings

Manufacturing Sequence

TOO LONG TIME FOR PRODUCT DEVELOPMENT

Additive Manufacturing
INTRODUCTION
The ASTM has defined Additive Manufacturing' AM) as a (ASTM
International, 2012): "process of joining materials to make objects
from 3D model data, usually layer upon layer, as opposed to
subtractive manufacturing methodologies, such as traditional
machining.

Fig 1. Bee-hive-An Analogy for AM

Additive Manufacturing (AM) - Principle

Slicing
3D CAD Data(STL File)

Physical part
Building of part on
RP M/c

Fig 3. Principle of Additive Manufacturing

Four major aspects of Additive Manufacturing

Fig .The Rapid prototyping wheel depicting the four major aspects of AM
(Source: Rapid Prototyping,Chua C.K, Leong K.E and Lim C.S)

Source : Wohlers Associates ,Inc

Time compression engineering

Fig . Time-Compression Engineering

(Source: Rapid Manufacturing, D. T. Pham and S.S. Dimov)

History of Additive Manufacturing

The roots of AM can be traced to two technical areas:
1. Topography
2. Photo sculpture.
TOPOGRAPHY:

A
layered
method
was
proposed by Blanther (1892)
for
making
moulds
for
topographical relief maps.

Both positive and negative 3D

surfaces
were
to
be
assembled from a series of
wax plates cut along the
topographical contour lines.

Fig . A method for making moulds for topographical relief maps [Blanther,1892]
(Source: Rapid Manufacturing, D. T. Pham and S.S. Dimov)

History of Additive Manufacturing

Photo sculpture

This is a technique [Bogart, 1979]

proposed in the 19th century for
creating replicas of 3D objects.
The
technique
involves
photographing
the
object
simultaneously with 24 cameras
equally spaced around a circular
room and then using the silhouette of
each photograph to carve 1/24th of a
cylindrical portion of the object.

Fig 6. The layer manufacturing system proposed by Munz [1956]

(Source: Rapid Manufacturing, D. T. Pham and S.S. Dimov)

History of Additive Manufacturing

Development work in the area of AM continued in the 1960s and 1970s and a
number of patents have been filed on different methods and systems. These
include:

A method for fabricating objects from powdered materials by heating particles

locally and fusing them together employing a laser, electron beam, or plasma
beam [Ciraud, 1972].

A process for producing plastic patterns by selective 3D polymerisation of a

photosensitive polymer at the intersection of two laser beams [Swainson,
1977].

A photopolymer RP system for building objects in layers [Kodama, 1981]. A

mask is used to control the exposure of the UV source when producing a
cross section of the model.

A system that directs a UV laser beam to a polymer layer by means of a

mirror system on an x-y plotter [Herbert, 1982].

Advantages of Additive Manufacturing

The benefits of RP systems can be categorized into direct and indirect benefits.

Direct benefits:
The ability to experiment with physical objects of any
complexity in are relatively short period of time.

Project time and product complexity in 25 years time frame

(Source: Rapid Prototyping,Chua C.K, Leong K.E and Lim C.S)

Advantages of Additive Manufacturing

Fig . Results of the integration of RP technologies

(Source: Rapid Prototyping,Chua C.K, Leong K.E and Lim C.S)

Advantages of Additive Manufacturing

The benefits of RP systems can be categorized into direct and indirect benefits.

Direct benefits:
The ability to experiment with physical objects of any
complexity in are relatively short period of time.

Project time and product complexity in 25 years time frame

(Source: Rapid Prototyping,Chua C.K, Leong K.E and Lim C.S)

Benefits to Product Designers

The product designers can increase part complexity with little
significant effects on lead time and cost.
They can reduce parts count by combining features in single-piece
parts that are previously made from several because of poor tool
accessibility or the need to minimize machining and waste.
With fewer parts, time spent on tolerance analysis, selecting
fasteners, detailing screw holes and assembly drawings is greatly
reduced.
There will also be fewer constraints in the form of parts design
without regard to draft angles, parting lines or other such
constraints.
Parts which cannot easily be set up for machining, or have accurate,
large thin walls, or do not use stock shapes to minimize machining
and waste can now be designed.
They can minimize material and optimize strength/weight ratios
without regard to the cost of machining.
They can minimize time-consuming discussions and evaluations of
manufacturing possibilities.

FREEDOM FOR DESIGNER

Design For Manufacture

Not Possible by
conventional processes

Benefits to Product Designers

They can minimize material and optimize strength/weight ratios without
regard to the cost of machining.

Fig: Load Bearing Hydraulic Manifold

Benefits to Product Designers

They can reduce parts count by combining features in single-piece parts that
are previously made from several because of poor tool accessibility or the need
to minimize machining and waste.

Benefits to the Tooling and

Manufacturing Engineer
The manufacturing engineer can minimize design, manufacturing
and verification of tooling.
He can also reduce parts count and, therefore, assembly,
purchasing and inventory expenses.
The manufacturer can reduce the labor content of manufacturing,
since part-specific setting up and programming are eliminated,
machining/casting labor is reduced, and inspection and assembly
are also consequently reduced as well.
Reducing material waste, waste disposal costs, material
transportation costs, inventory cost for raw stock and finished parts
(making only as many as required, therefore, reducing storage
requirements) can contribute to low overheads.
the manufacturer can simplify purchasing since unit price is almost
independent of quantity, therefore, only as many as are needed for
the short-term need be ordered.

Benefits to the Tooling and

Manufacturing Engineer
One can purchase one general purpose machine rather
than many special purpose machines and therefore,
reduce capital equipment and maintenance expenses,
need fewer specialized operators and less training.
Furthermore, one can reduce the inspection reject rate
since the number of tight tolerances required when parts
must mate can be reduced.
One can avoid design misinterpretations (instead, what
you design is what you get), quickly change design
dimensions to deal with tighter tolerances and achieve
higher part repeatability, since tool wear is eliminated.
one can reduce spare parts inventories (produce spare
on demand, even for obsolete products).

Benefits to the Tooling and Manufacturing Engineer

The manufacturing engineer can minimize design, manufacturing and verification of
tooling.

Plastic part

Core & Cavity

Build-time : 5 Hours

Indirect Benefits
Benefits to Marketing

It can greatly reduce time-to-market, resulting in

Reduced risk as there is no need to project customer needs and
market dynamics several years into the future.
Products which fit customer needs much more closely.
Products offering the price/performance of the latest technology
New products being test-marketed economically.
Marketing can also change production capacity according to market
demand, possibly in real time and with little impact on
manufacturing.
One can increase the diversity of product offerings and pursue
market niches currently too small to justify due to tooling cost
(including custom and semi-custom production).
One can easily expand distribution and
quickly enter foreign markets.

Indirect Benefits
Benefits to the Consumer

The consumer can buy products which meet more closely individual
needs and wants.
Much wider diversity of offerings to choose from.
Consumer can buy products at lower prices, since the manufacturers
savings
will ultimately be passed on.

Part complexity & cost

-Conventional/CNC

1.
2.
CNC milling M/c
Conventional milling M/c

Part Complexity

CNC milling M/c

EDM etc.,

Part complexity & cost

-AM Technology

Complexity of part

Aerospace
Turbine blades made by DMLS from EOS (a German
manufacturer of laser sintering/melting systems) have
found their way onto test rigs.
It is believed that a variety of metal parts made by
additive manufacturing will initially make their way onto
flying aircraft in 2-3 years and will become common in 10
years.
The opportunity is not only for flight hardware, but also
for jet-powered boats, land-based power generators, and
other applications of gas turbine engines.

Reference: David L. Bourell, Ming C. Leu, David W. Rosen, Roadmap for Additive Manufacturing Identifying the Future
of Freeform Processing, The University of Texas at Austin, Laboratory for Freeform Fabrication, 2009.

Biomedical
Many universities and research institutes are exploring
ways in which AM can be applied to medical implant
design and manufacturing, tissue engineering, and
regenerative medicine.
Two companies in Italy have used AM to manufacture
more than 10,000 metal hip implants, thousands of
which have been implanted into human beings.(The
average life span is increasing-Japan)
Meanwhile, Walter Reed Army Medical Center has
produced 37 cranial (Skull) implants using electron
beam melting, an AM process from Arcam of Sweden.
Reference: David L. Bourell, Ming C. Leu, David W. Rosen, Roadmap for Additive Manufacturing Identifying the Future
of Freeform Processing, The University of Texas at Austin, Laboratory for Freeform Fabrication, 2009.

Dentistry
The market for the production of dental products using
AM is on the verge of explosive growth.
Dental labs are using DMLS from EOS and other direct
metal AM processes for the production of copings for
crowns and bridges.
EOS has reported that the dental business is currently its
fastest growing area of AM for production applications.

Reference: David L. Bourell, Ming C. Leu, David W. Rosen, Roadmap for Additive Manufacturing Identifying the Future
of Freeform Processing, The University of Texas at Austin, Laboratory for Freeform Fabrication, 2009.

Automotive
High-end cars of small production are
candidates for using AM.
Bentley and Rover have shown that it is
feasible and have used AM for small,
complex parts.
Motorsports industry Helmet, car parts
Reference: David L. Bourell, Ming C. Leu, David W. Rosen, Roadmap for Additive Manufacturing Identifying the Future
of Freeform Processing, The University of Texas at Austin, Laboratory for Freeform Fabrication, 2009.

Defence
Many products for Defence are:
high value, complex, low volumes.

Some are customised such as

Unmanned aerial vehicles (UAVs),

Light-weight gear and armor for soldiers,
Portable power units,
Communication devices,
Ground-based robots,
Production of spare parts in remote locations,
Mobile parts hospitals, and legacy parts for aircrafts.

With AM improvements that are expected in 10-12 years, the military

will likely become a major user of additive manufacturing.

Reference: David L. Bourell, Ming C. Leu, David W. Rosen, Roadmap for Additive Manufacturing Identifying the Future
of Freeform Processing, The University of Texas at Austin, Laboratory for Freeform Fabrication, 2009.

Electronics
AM can produce 3D printed circuit boards that wrap
around the contours of the product.
Complex geometric features with multiple intake and
exhaust passages in a compact space for electrical
power generators can be fabricated using AM
The potential to use various materials is also attractive
because some parts of these reactors/generators should
be made of low conductivity materials (e.g., plastics)
whereas other parts require high conductivity and/or
catalytic properties (e.g., metals).
Reference: David L. Bourell, Ming C. Leu, David W. Rosen, Roadmap for Additive Manufacturing Identifying the Future
of Freeform Processing, The University of Texas at Austin, Laboratory for Freeform Fabrication, 2009.

Jewelry
In the future, jewelers will use AM to manufacture custom and
limited edition products.
Lionel Dean of Future Factories is currently manufacturing
impressive pendants in titanium alloys.
Lena Thorsson, formerly of Particular AB, showed that it is possible
to laser sinter gold alloys to produce beautiful chains and
necklaces that normally require complex and expensive machinery.

Reference: David L. Bourell, Ming C. Leu, David W. Rosen, Roadmap for Additive Manufacturing Identifying the Future
of Freeform Processing, The University of Texas at Austin, Laboratory for Freeform Fabrication, 2009.

Food
Specialty food is said to be a $13 billion industry.
With AM systems such as the open source Fab@Home machine
from Cornell University, it is possible to make chocolates and cake
icing that include 3D figures, company logos, names, and other
objects.
It is also possible to consider the use of AM system to manufacture
food products in cheese, peanut butter etc that can be extruded
through a syringe.

Reference: David L. Bourell, Ming C. Leu, David W. Rosen, Roadmap for Additive Manufacturing Identifying the Future
of Freeform Processing, The University of Texas at Austin, Laboratory for Freeform Fabrication, 2009.

Education
In 10-12 years, it is anticipated that schools will offer courses and
programs that include instruction on how to design for the
manufacture of parts using AM.

Innovative organizations will develop methods of product design that

take advantage of AM processes and materials.

Reference: David L. Bourell, Ming C. Leu, David W. Rosen, Roadmap for Additive Manufacturing Identifying the Future
of Freeform Processing, The University of Texas at Austin, Laboratory for Freeform Fabrication, 2009.

Distinction Between AM and CNC Machining

Following are range of topics where comparisons between CNC machining and
AM can be made.

Material
Speed
Complexity
Accuracy
Geometry
Programming

Distinction Between AM and CNC Machining

Material

AM
AM technology was
originally developed around
polymeric materials, waxes
and paper laminates.
Subsequently, there has
been introduction of
composites, metals,
and ceramics.

CNC Machining
CNC machining to make
final products, it works
particularly well for hard,
relatively brittle materials
like steels and other metal
alloys to produce high
accuracy parts with well
defined properties.

AM parts may have voids or CNC parts will normally be

anisotropy that are a
more homogeneous and
function of part orientation, predictable in quality.
process parameters or how
the design was input to the
machine.

SPEED

AM

CNC Machining

Shorter Lead time:

Irrespective of part complexity,
manufactured in single stage

Longer Lead time:

Multistage manufacturing process,
requiring repositioning or relocation of
parts within one machine or use of
more than one machine.

Setup and process planning time

remains same irrespective of part
complexity

Setup and process planning time,

increases particularly as parts become
more complex in their geometry.

Multiple parts are often batched

together inside a single AM build
which reduces setup lead time.

M/c and part set up is to be done

repetitively for each and every
component.

COMPLEXITY

AM
Irrespective of part complexity, parts are
produced in single setup and in the AM
machine

CNC
M/c Setup and No of machines to produce
a component depends on part complexity.

AM processes are not constrained in

the same way and undercuts and
internal features can be easily built
without specific process planning.

Since a machining tool must be

carried in a spindle, there may be
certain accessibility constraints or
clashes preventing the tool from being
located on the machining surface of a
part.

Possible to build parts in single setup

Certain parts cannot be fabricated by

CNC unless they are broken up into
components and reassembled at a
later stage.
Ex: a ship inside a bottle.

ACCURACY

AM

CNC

Diameter of the laser beam would

Wall thickness can be thinner
determine the minimum wall thickness. than the tool diameter since it is a
subtractive process.
The vertical build axis corresponds to
layer thickness and this
would be of a lower resolution
compared with the two axes in the
build plane

The accuracy of CNC machines is

mainly determined by positioning
resolution along all three orthogonal
axes and by the diameter of the rotary
cutting tools.

Geometry

AM

CNC

The vertical build axis corresponds to

layer thickness would be of a lower
resolution compared with the two axes
in the build plane.

The accuracy of CNC machines is

mainly determined by positioning
resolution along all three orthogonal
axes and by the diameter of the rotary
cutting tools.

Diameter of the laser beam would

Wall thickness can be thinner
determine the minimum wall thickness. than the tool diameter since it is a
subtractive process.

Programming

AM

CNC

AM machines have options that must

be selected, but the range, complexity
and implications surrounding their
choice are minimal in comparison.

Program sequence for a CNC

machine is more which includes tool
selection, machine speed settings,
approach position, and angle, etc.

The worst that is likely to happen in

most AM machines is that the part will
not be built very well if the
programming is not done properly.

Incorrect programming of a
CNC machine could result in severe
damage to the machine and may even
be a safety risk.

Preliminary Summarized Comparison

Area of Comparison

AM technology

CNC

Materials

Limited

Nearly Unlimited

Maximum part size

Varies

Large enough to handle aerospace

parts

Part Complexity

Unlimited

Limited

Feature detail

Varies

Varies

Accuracy

0.125mm to 0.75mm

0.0125mm to 0.125mm

Repeatability

Moderate

High

Surface Finish

2.5 to 15 microns

0.5 to 5 microns

Reliability

Moderate

Moderate to high

Staffing

Minimal

Significant

Skilled Labor

Minimal

Moderate to high

Lead time

Short to moderate

Moderate
41

http://www.moldmakingtechnology.com/articles/is-cnc-machining-really-better-than-rp

Part complexity & cost

-Conventional/CNC

1.
2.
CNC milling M/c
Conventional milling M/c

Part Complexity

CNC milling M/c

EDM etc.,

Part complexity & cost

-AM Technology

Complexity of part

AM V/S Conventional machining Time

RPT V/S Conventional machining - Cost

Mass Customization
Hearing aids, dental crowns and implants, medical prostheses, and the
high-end interior design and fashion industries are the areas where
there is a huge demand for unique products, but these niche areas were
not pursued owing to
the lower volumes
high degree of customization requirements
Increased automation in CAD software now is being extended to
encompass other industries, including consumer product industries.

Individually customized mass-produced hearing aid shells

46
Gilmar Ferreira Batalha et. al. & Laser-Sintering for Hearing Aids, Dental Restorations, EOS

AM Max. size of part,

Accuracy
Sl.No.

RP
Process

1
2
3
4

SLA
FDM
LOM
SLS

DMLS

Maximum
size of part
(mm)

Dimensional
Accuracy (mm)

508 X 508 X 600

0.1
0.127
0.127

600 X 500 X 600

813 X 559 X 508

381 X 330 X 457

0.1

250 X 250 X 150

0.05