Additive Manufacturing; Present And Future

Additive Manufacturing; Present And Future. Presented by, Stephin Abraham Sabu S7 ME B Roll No. 48.

CONTENTS. Introduction What is additive manufacturing? Functional principle Advantages & disadvantages Applications AM Processes Present conditions AM - Future Aspects Gaps & needs Recommendations Conclusion.

Introduction. Manufacturing is a process in which raw materials are transformed into finished goods. Additive Manufacturing Technology that can make anything. Eliminates many constraints imposed by conventional manufacturing Leads to more market opportunities. Increased applications such as 3D faxing sender scans a 3D object in cross sections and sends out the digital image in layers, and then the recipient receives the layered image and uses an AM machine to fabricate the 3D object..

[image] Desired Shape Actual Shape from Additive Manufacturing Machine.

[image] Materials Development 3D CAD Model 'Design,¯ Modelling & Simulation Materials processing & la erin .sn File Sliced Layers & Tool Path PRINTINö 3D Printer 3D Object.

ADVANTAGES Freedom of design Complexity for free Potential elimination of tooling Lightweight design Elimination of production steps DISADVANTAGES Slow build rates High production costs Considerable effort required for application design Discontinuous production process Limited component size..

Applications. AM has been used across a diverse array of industries, including; Automotive Aerospace Biomedical Consumer goods and many others.

AM processes are classified into seven categories Vat Photopolymerisation/Steriolithography Material Jetting Binder jetting Material extrusion Powder bed fusion Sheet lamination Directed energy deposition.

Vat photopolymerization/Steriolithography. Laser beam traces a cross-section of the part pattern on the surface of the liquid resin SLA's elevator platform descends A resin-filled blade sweeps across the cross section of the part, re-coating it with fresh material Immersed in a chemical bath Stereolithography requires the use of supporting structures.

Material Jetting. Drop on demand method The print head is positioned above build platform Material is deposited from a nozzle which moves horizontally across the build platform Material layers are then cured or hardened using ultraviolet (UV) light Droplets of material solidify and make up the first layer. Platform descends Good accuracy and surface finishes.

Binder Jetting. A glue or binder is jetted from an inkjet style print head Roller spreads a new layer of powder on top of the previous layer The subsequent layer is then printed and is stitched to the previous layer by the jetted binder The remaining loose powder in the bed supports overhanging structures.

Material Spod Heater Element Suport Material BuiW Platform.

Powder Bed Fusion. Selective laser sintering (SLS) Selective laser melting (SLM) Electron beam melting (EBM) No support structures required.

Sheet Lamination. Metal sheets are used Laser beam cuts the contour of each layer Glue activated by hot rollers.

Directed Energy Deposition. Consists of a nozzle mounted on a multi axis arm Nozzle can move in multiple directions Material is melted upon deposition with a laser or electron beam.

Present Condition & Trends. Technology And Research The model data, usually in stereolithography (STL) format, is first decomposed into a series of 2D, finitely thick cross sections, which are then fed into an AM machine. Used directly and indirectly to produce prototype parts Reduce manufacturing and product costs University–Industry Collaboration and Technology Transfer More and more companies have begun using AM technology to; Reduce time-to-market Increase product quality Improve product performance Costs.

Metal-based AM processes have recently emerged in industrial applications for manufacturing items such as automotive engines, aircraft assemblies, power tools, and manufacturing tools including jigs, fixtures, and drill guides Education And Training Educating the general public about AM empowers people to build what they dream. Formal AM education has already been integrated into curricula at different levels. Educational materials on rapid prototyping have long been a part of manufacturing engineering courses.

AM - Future Aspects. Technology And Research “ Third industrial revolution “ The cost effective mass customization of complex products Reduced material waste and energy consumption Adapt new product designs without the additional expenses In the biomedical field, AM can be used to fabricate tissue scaffolds that are biocompatible, biodegradable, and bio-absorbable Education & Training AM holds great potential for promoting science, technology, engineering, and mathematics (STEM) education The availability of low-cost 3D printing equipment is creating the opportunity for AM-enabled, hands-on labs in primary, secondary, and postsecondary schools across the nation.

Gaps & Needs. Technology and Research. System integration and cyber implementation Materials development and evaluation Design methodology and standards Modeling, monitoring, control, and rocesses Characterization and certification Fig. 1 Four essential technology elements and system integration for viable AM.

Material Intensive materials research and development is needed In metallurgy, it takes about 10 years to develop a new alloy, including the determination of various critical properties such as fatigue strength. This time frame also applies to developing new materials for AM Even with existing materials, advancements are needed Design Various AM-oriented design tools must be developed CAD systems should be re-invented to overcome its limitations Modeling, Sensing, Control, and Process Innovation Difficult to predict the microstructures and fatigue properties resulting from AM processes The sensing of AM processes may require fast in situ measurements of the temperature, cooling rate, and residual stress Characterization and Certification Real production environments and practices are much more rigorous than those for prototyping purposes. The existing AM systems are still predominantly based on rapid prototyping machine architectures.

[image] VISIBILITY (Expectation) Peak Of Inflated Expectations Additive manufacturing 3D printing Plateau of Productivity Slope of Enlightenment Trough of Disillusionment Technology Trigger Fig. 2 Position of AM on the hype curve TIME.

Hype Curve. 22. [image] NO. 1 2 3 4 5 Phase Technology Trigger Peak of Inflated Expectations Trough Of Disillusionment Slope ot Enlightenment Plateau of Productivity Description A potential technology breakthrough kiCkS things Off. Early proof-ot-concept stories and media interest trigger significant publicity. Often no usable products exist and commercial viability is unproven. Early publicity produces a number of success stories—often accompanied by scores of failures. Some companies take action; many do not. Interest wanes as experiments and implementations fail to deliver. Producers of the technology snake out or fail. Investments continue only if the surviving providers improve their products to the satisfaction of early adopters. More instances Of how the technology can benefit the enterprise start to crystallize and become more widely understood. Second- and third-generation products appear from technology providers. More enterprises fund pilots; conservative companies remain cautious. Mainstream adoption starts to take Off. criterja tor assessing provider viability are more Clearly defined. The technology's broad market applicability and relevance are clearly paying off.

Education & Training While numerous AM education resources and training materials are available, there is still no readily applicable, proven model for AM education and training Taking full advantage of AM will require; Educating the current workforce Recruiting a new generation of students Developing proper design tools.

Recommendations. Technology and Research. Materials Development of new materials for AM processes Formation and mixing of materials in desired forms and with desired properties Design Methods and tools for simultaneous multifunctional Product design and AM process design Modeling Robust physics-based mathematical models of temperature, stress etc. Prediction of microstructures and fatigue properties resulting from extreme heating and cooling rates in AM processes Sensing and control Fast-response sensors for detecting defects and phase transformations Integrated real time sensing and closed-loop control of AM processes The production costs, manufacturing time, and part defects must be reduced drastically in order for AM to become hugely successful..

University–Industry Collaboration and Technology Transfer Collaborations incentivized by federal funding programs Increased federal research and development (R&D) support Education and Training Teaching Factory In the teaching factory, students are exposed directly to a manufacturing enterprise where they design products to meet customer needs and manufacture their designed products for the market. Other Training Efforts Promotion of public awareness Use of the Internet Establishment of publicly accessible AM facilities.

CONCLUSION. The process of joining materials to make objects from three-dimensional (3D) model data, usually layer by layer Traditional subtractive machining techniques rely on the removal of material by methods such as cutting or milling Has many advantages over traditional manufacturing processes Seven processes of AM AM is on the verge of shifting from a pure rapid prototyping technology Manufacturing metal components with virtually no geometric limitations or tools offers new ways to increase product performance or establish new processes and revenue streams.

References. Base Journal ; Additive Manufacturing: Current State, Future Potential, Gaps and Needs, and Recommendations ASTM, 2009, ASTM International Committee F42 on Additive Manufacturing Technologies, ASTM F2792–10 Standard Terminology for Additive Manufacturing Technologies, ASTM, West Conshohocken, PA. Wohlers Associates, Inc., 2013, Wohlers Report 2013: Additive Manufacturing and 3D Printing State of the Industry, Wohlers Associates, Fort Collins, CO. Bourell, D. L., Beaman, J. J., Leu, M. C., and Rosen, D. W., 2009, “A Brief History of Additive Manufacturing and the 2009 Roadmap for Additive Manufacturing: Looking Back and Looking Ahead,” Proceedings of RapidTech 2009: US-TURKEY Workshop on Rapid Technologies, Istanbul, Turkey, Sept. 24–25, pp. 1–8. Google Wikipedia.

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