ADDITIVE MANUFACTURING

Gourav Kamboj (2014ME20729)

Karan Jindal (2014ME10107)

Department of Mechanical Engineering

 DEFINITION
‘Additive Manufacturing (AM) refers to a process by which digital 3D design
data is used to build up a component in layers by depositing material’[1]

What You See Is What You Build (WYSIWYB) Process

● Builds parts Layer-By-Layer

● Class of technologies that construct physical models from CAD data
● Somewhat like a 3D printer
● An Additive process
● Visual Aids or Design Testing
● Rapid Tooling or Rapid Production of parts
Source: http://www.design.lth.se/
 Basic Process
● Create a CAD model of the design
● Convert the CAD model to STL format
● Slice the STL file into thin cross-sectional layers
● Construct the model one layer atop another
● Clean and finish the model

CAD Model STL Format

Source: Gibson, Additive

 Additive Manufacturing Techniques
Laminated Object Manufacturing

• Called LOM

• Paper is coated heat-activated glue so it will stick. (spool)

• Paper is bonded with last piece with heated rollers.
• Design is cut out of paper with a laser.
• The excess paper is cross hatched for removal.
• Produces large parts.
• Wood like texture
 LOM Cont..

Source:http://home.iitk.ac.in/~nsinha/Additive_Manufacturing%20II.pdf
 Selective Laser Sintering

● Called SLS
● Melts powdered material a layer at a time.
○ Uses levelling rollers
● Laser is used to melt powdered material.
○ Traces part and sintering metal powder
● Makes functional parts.
● Many different powders can be used.

Source:IOSR Journal, A Review on Selective Laser Sintering by K.R. Bakshi, A. V. Mulay

 SLS Condi….

SLS Process Laser Sintering Nomenclature

Source:IOSR Journal, A Review on Selective Laser Sintering by K.R. Bakshi, A. V. Mulay

 Fused Deposition Modeling

● Second Most Widely Used

● Filament of heated thermoplastic is extruded from the tip
● X-Y plane
● Like decorating a cake
● Platform lowered and head deposits a second layer upon the first
● ABS, PC, Casting Wax, Polyphenylsulfone
 FDM Conti….

FDM Process Extruder

Source: http://www.custompartnet.com/
 BAAM Technique
● Big Area Additive Manufacturing
● Newly Developed
● Extrude hot thermoplastic material along specific tool paths to generate three-
dimensional shapes
● BAAM technology uses a single-screw extruder to melt a pelletised feedstock similar
to that used in the injection moulding industry

● The single-screw extruder is also capable of depositing material at a rate that is 200
faster (up to 50 kg/h) than conventional polymer AM systems
● The BAAM build platform can accommodate structures as large as 6 m in length, 2.4
m in width and 1.8 m in height, which is 10 larger than most commercial systems
 BAAM Machine
Video Link: https://www.e-ci.com/baam/

BAAM with Enclosure BAAM Inside

Source:www.e-ci.com
 Sources
1. International Committee F42 for Additive Manufacturing Technologies, ASTM
2. https://www.e-ci.com/
3. https://www.emeraldinsight.com/doi/full/10.1108/RPJ-12-2015-0183
4. https://additivemanufacturingllc.com/services/selective-laser-sintering/
5. http://www.iosrjournals.org/iosr-jmce/papers/Conf15008/Vol-4/53-57.pdf
6. http://www.padtinc.com/rm/sla/default.htm
7. http://www.webworqs.com/nomura/stereo.html
8. http://www.howstuffworks.com/stereolith3.htm
9. http://www.nsf.gov/od/lpa/news/02/3dprinttip_images.htm
10. http://web.mit.edu/tdp/www/whatis3dp.html
11. http://web.mit.edu/tdp/www/applications.html
12. http://www.zcorp.com/content/product_info/keyadvantages.html