MME 9651
Additive Manufacturing
Lecture 02
Additive Manufacturing Processes
September 21, 2021
Dr. Mostafa Yakout
Additive
Manufacturing
Processes
Liquid Filament Powder Solid Layer
Processes Processes Processes Processes
VAT
Photopolymerization Material Extrusion Powder Bed Sheet Lamination
(VPP) (MEX) Fusion (PBF) (SHL)
Material Jetting Directed Energy
(MJT) Deposition (DED)
Binder Jetting
(BJT)
Copyright © M. Yakout 1
1. Vat photopolymerization
Wind tunnel designed
for Lotus Formula 1
Courtesy of 3D Systems
• A photosensitive liquid (thermoset photopolymer) in a vat is cured by light-
activated polymerization.
• Feedstock materials are radiation-curable resins or photopolymers in the
liquid state. They become solid via chemical reactions upon irradiation.
• Most photopolymers react to radiation in the ultraviolet (UV) range of
wavelengths, but some visible lights are also used.
Copyright © M. Yakout 2
1. Vat photopolymerization (cont’d)
[Link]
Copyright © M. Yakout 3
2. Material jetting
• Droplets of feedstock material are
deposited in specific locations on
a build platform that is bathed in
the cross-linking electromagnetic
radiation.
• Feedstock materials are:
a) Photopolymers similar to those
used in vat photopolymerization.
b) Melted polystyrene, polyethylene,
polymers, acrylonitrile butadiene
styrene (ABS), polycarbonate,
and polypropylene.
• The viscosity of the feedstock
must be sufficiently low to enable
formation of a fine droplet stream.
Copyright © M. Yakout 4
2. Material jetting (cont’d)
[Link]
Copyright © M. Yakout 5
Carbon 3D printing
[Link]
Copyright © M. Yakout 6
Additive
Manufacturing
Processes
Liquid Filament Powder Solid Layer
Processes Processes Processes Processes
VAT
Photopolymerization Material Extrusion Powder Bed Sheet Lamination
(VPP) (MEX) Fusion (PBF) (SHL)
Material Jetting Directed Energy
(MJT) Deposition (DED)
Binder Jetting
(BJT)
Copyright © M. Yakout 7
3. Material extrusion
• Filament feedstock is forced
through a nozzle that moves
relative to a build platform.
Example: cake icing ☺
• The feedstock material is heated
in the liquefier chamber.
• Feedstock materials are polymer
matrix composites, polymers,
and slurries.
Large-area material extrusion
Courtesy of University of Southern California
Copyright © M. Yakout 8
3. Material extrusion (cont’d)
[Link]
Copyright © M. Yakout 9
Additive
Manufacturing
Processes
Liquid Filament Powder Solid Layer
Processes Processes Processes Processes
VAT
Photopolymerization Material Extrusion Powder Bed Sheet Lamination
(VPP) (MEX) Fusion (PBF) (SHL)
Material Jetting Directed Energy
(MJT) Deposition (DED)
Binder Jetting
(BJT)
Copyright © M. Yakout 10
4. Powder bed fusion
• Powder feedstock is spread over a build platform in a thin layer on the
order of 30-100 m.
• A thermal energy source fuses regions of the powder bed.
a) Laser-based: Selective Laser Melting (SLM), Laser Cusing, etc.
b) Electron beam: Electron Beam melting (EBM)
Complex PBF parts. Courtesy of 3D Systems
Copyright © M. Yakout 11
4. Powder bed fusion (cont’d)
Copyright © M. Yakout 12
5. Directed energy deposition
Repairing a titanium turbine compressor vane
Courtesy of Optomec, Inc.
• Powder or wire feedstock is deposited through a nozzle, then a focused
thermal energy source (laser, electron beam, and plasma arc) melts the
material as it is being deposited.
• It is possible to deposit large amounts of material, particularly with wire-
fed processes, typically 508 to 1016 cm3/min.
Copyright © M. Yakout 13
5. Directed energy deposition (cont’d)
[Link]
Copyright © M. Yakout 14
6. Binder jetting
• A liquid bonding agent (binder) is selectively deposited into a bed of
powder feedstock to produce a part.
• Only small portion of the part material is delivered through the print head.
These binder droplets (80 μm in diameter) form spherical agglomerates of
binder liquid and powder particles as well as provide bonding to the
previously printed layer.
Copyright © M. Yakout 15
6. Binder jetting (cont’d)
[Link]
Copyright © M. Yakout 16
Additive
Manufacturing
Processes
Liquid Filament Powder Solid Layer
Processes Processes Processes Processes
VAT
Photopolymerization Material Extrusion Powder Bed Sheet Lamination
(VPP) (MEX) Fusion (PBF) (SHL)
Material Jetting Directed Energy
(MJT) Deposition (DED)
Binder Jetting
(BJT)
Copyright © M. Yakout 17
7. Sheet lamination
• Binding and shaping of sheet feedstock.
• Sheets of feedstock material are being bonded using a polymer-based
adhesive. These sheets are precisely cut using a laser or mechanical
cutter.
Copyright © M. Yakout 18
7. Sheet lamination (cont’d)
[Link]
Copyright © M. Yakout 19
History of
Additive Manufacturing
Copyright © M. Yakout 20
Industrial revolution
Industry 4.0
Industry 3.0
Industry 2.0 Digitalization
Industry 1.0 Automation Cyber-physical systems,
internet of things (IoT),
Electrification Numerical control, networks
computers, electronics
Mechanization Mass production,
assembly lines
Steam power, weaving
loom
1784 1870 1969 2011
Copyright © M. Yakout 21
Additive manufacturing precursors (1968–1984)
Laser crossed- Sand powder Benchtop vat
beam approach fusion polymerization
Swainson Housholder Herbert
USA 1968 USA 1979 1982
Weld metal Freeform Moveable weld
deposition photopolymer head freeform
Ciraud Kodama Bronowski
Germany 1972 1981 USA 1984
Copyright © M. Yakout 22
Modern additive manufacturing (1981-Late 2000s)
• Helisys company by Feygin
• Stack-and-cut sheet lamination process
1985 • The company closed in 2000
VPP, 3D
Systems
• Denken venture in Japan 1987
• First stereolithography machine in 1993 DED, SHT,
1985 Optomec Helisys
1998 1991
• 3D Systems company by Chuck Hull
• First commercial SLA machine in 1987
1986 • Developed the STL file format AM
MJT, System MEX,
Sanders
Stratasys
Prototype
• Japan’s NTT Data CMET and Sony/D- 1994
1991
MEC
1988 • Stereolithography commercial machines
PBF,
BJT,
DTM
Soligen
• Electro Optical Systems (EOS) of Corp.
1993
Germany sold its first stereolithography 1992
1990 system
Copyright © M. Yakout 23
Commercialization of additive manufacturing
• Chuck Hull, the founder of 3D Systems company, developed the first
additive manufacturing machine in 1987. This process is named
stereolithography, that is where the STL name came from.
• Stratasys (1991)
• EOS (1994)
• Optomec (1998)
• Concept Laser (2000) – now GE
• Renishaw (2011)
• SLM Solutions (2014)
Copyright © M. Yakout 24
Additive manufacturing industry
Copyright © M. Yakout 25
Classifications for AM
• There are many commercial terms for AM:
Additive Rapid Automated Freeform
3D printing
fabrication prototyping fabrication fabrication
Rapid Direct digital Solid freeform Layer-based Automated
manufacturing manufacturing fabrication manufacturing manufacturing
• Classification of AM systems
Basis of classification AM systems
Materials being processed plastics, metals or ceramics
Energy source binder, laser, electron beam or heated nozzle
Feedstock state solid (powder, wire or sheet) or liquid
Copyright © M. Yakout 26
Development of AM file formats (ISO/ASTM 52915)
• Initial Graphics Exchange Specification (IGES)
CAD data exchange format intended for exchange of product geometry and
geometry information.
• Additive Manufacturing File Format (AMF)
File format for communicating additive manufacturing model data including a
description of the 3D surface geometry with native support for colour, materials,
lattices, textures, constellations and metadata.
• Standard Tessellation Language (STL)
File format for model data describing the surface geometry of an object as a
tessellation of triangles used to communicate 3D geometries to machines in
order to build physical parts.
Copyright © M. Yakout 27
Steps of additive manufacturing
Copyright © M. Yakout 28
References
• Bourell D.L., Frazier, W., Kuhn, H., Seifi, M. (editors). ASM Handbook,
Volume 24: Additive Manufacturing Processes. ASM International 2020.
Chapters 1 & 2.
• Gibson, I., Rosen, D., Stucker, B. Additive Manufacturing Technologies:
3D Printing, Rapid Prototyping, and Direct Digital Manufacturing. 2nd
Edition. Springer 2015.
• ASTM International, Standard Terminology for Additive Manufacturing –
General Principles – Terminology. ISO / ASTM52900 (2015).
Copyright © M. Yakout 29
Assignment 1
Copyright © M. Yakout 30
Thank You
