Introduction to Additive Manufacturing
Prof. Deepak Marla,
Associate Professor
Department of Mechanical Engineering
Indian Institute of Technology Bombay
Textbook Reference: Ian Gibson et al., Additive Manufacturing Technologies, Springer (2015).
ME 323 Professor
Deepak Marla, Associate Thermal
ME and Chemical
323: Thermal Processing
and Chemical of Materials
Processing of Materials
Additive Manufacturing: Design, Processes and Inspection
Additive Manufacturing
• Involves building of 3D objects by adding layer upon layer
material
• Uses 3D modeling software, layer material and machine
equipment
• The AM equipment reads in data from the CAD file and adds
successive layers of material to fabricate the object
• Also called as 3D Printing, but AM is more technical term.
additive fabrication, additive processes, additive techniques, additive layer
manufacturing, layer
manufacturing,
Deepak Marla, Associatesolid freeform fabrication
Professor and
ME 323: Thermal andfreeform fabrication
Chemical Processing 2
of Materials
Nature Inspired
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ME 323: Thermal and Chemical Processing of Materials
Nature Inspired
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ME 323: Thermal and Chemical Processing of Materials
Source: Manufacture 3D
Deepak Marla, Associate Professor ME 323: Thermal and Chemical Processing of Materials
Traditional Process vs
AM
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ME 323: Thermal and Chemical Processing of Materials
Traditional Process vs
AM
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ME 323: Thermal and Chemical Processing of Materials
Term: 3D Printing/Additive
Manufacturing
2D 3D
Printing Printing
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ME 323: Thermal and Chemical Processing of Materials
Additive Manufacturing: Design, Processes and Inspection
History
Full Body Organs/ Nano
Printing
2018-32
Bio Medical
Implants
Composites/energy
2014-18
sector
2012
AM for
Aerospace
2004
Rapid Tooling
Automotive
1998-94
Applications
Rapid Prototy
ping 1998-94
Sintering of metal/ceramic powder Photopolymerization Kodama, Rev Sci
Housholder, 1979 (Patent) Instr. 1981
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ME 323: Thermal and Chemical Processing of Materials
Additive Manufacturing: Design, Processes and Inspection
Why is AM such a big deal
now?
The wide availability of CAD/CAM software.
• Improved automation and component
technologies.
• A growing library of ‘printable’ materials.
• Major industry and government
investment.
• Freedom to operate enabled by patent 2020: $9.2B AM machines and services
Worldwide MFG is ~$15 trillion (16% of the world
economy) AM = 0.03%.
expirations.
Deepak Marla, Associate
• Momentum, Professorand creative
confidence, 10
ME 323: Thermal and Chemical Processing of Materials
Additive Manufacturing: Design, Processes and Inspection
Applications
Topological Optimizati
on
Food 3D
printing
Patient Specific 3D printing Bridge in
Implants/Models Amsterdam Aeronautical
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ME 323: Thermal and Chemical Processing Engines/part
of Materials
Additive Manufacturing: Design, Processes and Inspection
Why Additive
Manufacturing
Fast prototyping
Complex geometries
Multiple materials
New materials
Enhanced performance
Low-volume
Customization
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ME 323: Thermal and Chemical Processing of Materials
Additive Manufacturing: Design, Processes and Inspection
Why Additive
Manufacturing
Fast prototyping
Complex geometries
Multiple materials
New materials
Enhanced performance
Low-volume
Customization
Deepak Marla, Associate Professor 13
ME 323: Thermal and Chemical Processing of Materials
Additive Manufacturing: Design, Processes and Inspection
Why Additive
Manufacturing
Fast prototyping
Complex geometries
Multiple materials
New materials
Enhanced performance
Low-volume
Customization
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ME 323: Thermal and Chemical Processing of Materials
Additive Manufacturing: Design, Processes and Inspection
Cost and Time Saving
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ME 323: Thermal and Chemical Processing of Materials
Additive Manufacturing: Design, Processes and Inspection
Example
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ME 323: Thermal and Chemical Processing of Materials
Additive Manufacturing: Design, Processes and Inspection
Process Chain
Step 1: CAD
Step 2: Conversion to STL
Step 3: Transfer to AM Machine and STL File
Manipulation with Slicing
Step 4: Machine Setup
Step 5: Build
Step 6: Removal
Step 7: Post-Processing and Inspection
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ME 323: Thermal and Chemical Processing of Materials
Data Formats
STL— (Standard Tessellation Language)
• System-neutral data format for exchanging pure geometric
coordinates.
• Boundary surfaces of volume models are described by triangles
(planar facets) and normal vectors.
• STL data sets can be stored using either ASCII or binary
representations, the former being a more human-readable
format, the latter substantially reducing the file size.
• STL data format is unsuitable for exchanging data between
CAD/ CAM systems because the geometry is irreversibly faceted
ISO/ASTM 52950:2021(E) Additive manufacturing — General principles — Overview of
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Thermal and Chemical Processing of Materials
Approximation
• Is the maximum division between the designed part
and triangulation
• Generally, it is represented by chord height
• It is the maximum distance from the surface of original
design and STL mesh.
• It is recommended to insert tolerance between 0.01
mm and 0.001 mm
• It usually results in good-quality prints
• It controls the maximum angle normal vectors of each
triangle.
• Smaller value results in dense tessellation in curved
surfaces.
• It increases both resolution and file size.
• Deepak
Angle Marla,
tolerance controls
Associate the maximum
Professor angle
ME 323: between
Thermal 19
and Chemical Processing of Materials
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ME 323: Thermal and Chemical Processing of Materials
Slicing in 3D Printing
• The act of converting a 3D model into a set of
instructions for the 3D printers is called Slicing.
• Quite literally, it ‘slices’ the 3D model into thin
layers, and further determine how each layer
should be printed (the tool path) to get minimum
time, best strength, etc.
• A slicer software takes a 3D CAD model which is
generally an STL format file and converts it into
a g-code that gives commands to the printer.
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Deepak ME 323: Thermal and Chemical Processing of Materials 21
Components of a slicing software
• Like every software, we can divide it into two components — front-end & backend, OR — GUI and Logic.
• The front-end consists of the parts that the user directly interacts with. This is where the user visualizes the
CAD, as well as the gCode and tool path.
• The back-end components contain algorithms or instructions for the code execution.
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G-Code M-Code Example
Example
G1 X90 Y50 Z0.5 F3000 E1 tells the printer to move
in a straight line (G1) towards the final coordinates
X = 90 mm, Y = 50 mm, Z = 0.5 mm at a feed rate
(F) of 3,000 mm/min while extruding (E) 1 mm of
material in the extruder.
Deepak Marla, Associate Professor ME 323: Thermal and Chemical Processing of Materials
Layer Height
• The resolution of a 3D object is highly
dependent on its layer height.
• Smaller layer heights give high resolution and
smooth surface.
• However, the overall printing time could be
more.
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Infill patterns
• Infill density is measured in % percentage. It can range
from 0–100%.
• An object with 0% will have a hollow interior and an
object with 100% density will be solid.
• Objects with high density will have a longer printing time.
• The recommended shape for the infill for optimal speed
and strength is a honeycomb structure.
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Print Paths
• An optimized printing path is crucial to Additive
Manufacturing.
• It affects printing time, surface roughness, strength, etc.
• Printing paths have a direct impact on the time taken to
complete a certain print. A path planning strategy can
help optimize the overall printing process.
• This will result in a shorter fabrication time. Slicer
software has pre-defined print paths that one can select
from.
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Materials
Polymers
and Biomateri Construct
Metal Ceramics
composite als ion
s
• Photopolymer
• Acrylate Resin • Titanium • Phosphate • Bioinks • Cement
• Bio-based alloys calcium • Cell laden • Concrete
• Thermoplastics
Acrylate • Nickel carbonate Hydrogels • Fiber
• Acrylonitrile- alloys • Silica • Drugs Reinforced
Butadiene- • Aluminium • Calcium • Pharmaceuti Concrete
Styrene (ABS) • Portland
alloys Silicate cal material
• Poly-Carbonate Cement
• Steels • Alumina
(PC) • Calcium
• Polylactic Acid • Copper • Akermanite
(PLA) • Magnesiu • Ceramic matrix Aluminate
• Nylon6 based nano m composite • Polymer
composite Foam
• Carbon fibre
reinforced plastic
• Glass fibre
reinforced plastic 27
Deepak Marla, Associate Professor ME 323: Thermal and Chemical Processing of Materials
Functional Graded
Materials
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ME 323: Thermal and Chemical Processing of Materials
Functional Graded
Materials
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ME 323: Thermal and Chemical Processing of Materials
Hybrid Manufacturing: Additive
+ Subtractive
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Classification as per
Vat ASTM
Material Binder
Photopoly
Jetting Jetting
merization
Material Sheet Powder
Extrusion Lamination Bed Fusion
Directed
Energy
Deposition
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Vat Polymerization
vat photopolymerization (VPP), process in which liquid photopolymer in a
vat is selectively cured by light-activated polymerization.
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Material Jetting
material jetting (MJT), process in which droplets of feedstock material are selectively
Deepak Marla, Associate Professor ME 323:deposited.
Thermal and Chemical Processing of Materials 33
Binder Jetting
binder jetting (BJT), process in which a liquid bonding agent is selectively deposited to join
Deepak Marla, Associate Professor powder materials.
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Material Extrusion
material extrusion (MEX), process in which material is selectively dispensed through a
nozzle or orifice.
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Sheet Lamination
sheet lamination (SHL), process in which sheets of material are bonded to form a
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Powder Bed Fusion
powder bed fusion (PBF), process in which thermal energy selectively fuses regions of a
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powder 37
and Chemical Processing of Materials
bed.
Direct Energy Deposition
directed energy deposition (DED), process in which focused thermal energy is used to fuse
materials by melting as they are being deposited.
An energy source is focused to melt the materials being deposited.
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Energy Comparison
• Vat photopolymerization (SLA): material is cured by light-
activated polymerization.
• Material jetting (Object): droplets of build material are jetted to
form an object.
• Binder jetting (3DP): liquid bonding agent is jetted to join
powder materials.
• Material extrusion (FFF/FDM): material is selectively dispensed
through a nozzle and solidifies.
• Sheet lamination (LOM): sheets are bonded to form an object.
• Powder bed fusion (SLS/SLM): energy (typically a laser or
electron beam) is used to selectively fuse regions of a powder bed.
• Directed energy deposition (LENS): focused thermal energy is
used to fuse materials by melting as deposition occurs.
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Deepak Marla, Associate Professor ME 323: Thermal and Chemical Processing of Materials
