ME-101

Assignment
Submitted by: Devkriti Sharma
Roll no.:23bee035
Section:H
Submitted to: Dr Deepak Sharma

ADDITIVE MANUFACTURING AND

RAPID PROTOTYPING
Rapid prototyping is the technique of fabricating a prototype model from a
CAD file. In other words, 3D printing/additive manufacturing is the process,
and rapid prototyping is the end result. Rapid prototyping is one of many
applications under the 3D printing/additive manufacturing umbrella.

Additive manufacturing (AM) or additive layer manufacturing (ALM) is the

industrial production name for 3D printing, a computer controlled process that
creates three dimensional objects by depositing materials, usually in layers.

Evolution of Additive Manufacturing:

The first commercial 3D printing technology were released in the 1980s, which
is when additive manufacturing initially emerged. With the creation of
numerous printing techniques including Stereolithography (SLA), Selective
Laser Sintering (SLS), Fused Deposition Modeling (FDM), and others, AM has
advanced significantly since that time. The range of AM applications has
increased thanks to these techniques, which now include end-use component
production as well as tooling and prototyping.

. There are several steps involved in the generic additive manufacturing

process:

1. Digital Design
The process begins with the creation of a digital 3D model of the object to be
manufactured. This can be done using computer-aided design (CAD) software
or by scanning an existing object using 3D scanning technologies.

2. Slicing:
The digital model is sliced into thin horizontal layers using slicing software.
Each layer represents a cross-section of the object that will be built layer by
layer during the printing process.
3. Printing:
The sliced layers are sent to the 3D printer, which interprets the instructions and
builds the object layer by layer. Various additive manufacturing technologies
may be used, each with its own printing process and materials.

4. Post-Processing:
After printing is complete, the object may undergo post-processing steps to
improve surface finish, strength, or other properties. This can include removing
support structures, sanding, polishing, or applying additional treatments or
coatings.
CLASSIFICATION OF AM PROCESSES
Liquid-based stereolithography:
Using a UV laser, layers of a liquid photopolymer resin—commonly referred to
as resin—are cured during this additive manufacturing technique. Larger,
industrial systems and smaller, desk-top models are available for 3D SLA
printers.

Preparation: The first step in the procedure is to create a digital 3D model of the
item that has to be made. With the use of specialist software, this model is
divided into thin cross-sectional layers.

Resin Vat: The liquid photopolymer resin is kept in a container known as a resin
vat or tank. The build platform starts out just below the liquid resin's surface
and gradually rises as the object is constructed layer by layer.

Laser Exposure: The liquid resin's surface is exposed to a UV laser beam.

Fused deposition modeling (FDM) (Liquid Based):

Fused deposition modeling (FDM) 3D printing, also known as fused filament
fabrication (FFF), is an additive manufacturing (AM) process within the realm
of material extrusion. FDM builds parts layer by layer by selectively depositing
melted material in a predetermined path. It uses thermoplastic polymers that
come in filaments to form the final physical objects.
It involves the following steps:
Preparation: The process begins with the creation of a 3D digital model using
Computer-Aided Design (CAD) software. This model is then sliced into thin
horizontal layers using slicing software, which generates instructions (G-code)
for the 3D printer.

Material Preparation: Thermoplastic filaments, usually in the form of a spool,

are loaded into the FDM printer. Common materials include PLA (Polylactic
Acid), ABS (Acrylonitrile Butadiene Styrene), PETG (Polyethylene
Terephthalate Glycol), and others.

Printing: The FDM printer heats the thermoplastic filament to its melting point,
typically within a nozzle attached to a movable print head. The nozzle moves
along the X, Y, and Z axes according to the instructions from the slicing
software. As the nozzle moves, it extrudes the molten material onto the build
platform, forming each layer of the object.

Layer-by-Layer Building: The process repeats layer by layer, with each new
layer bonding to the previous one as it cools and solidifies. The build platform
gradually moves downward (or the print head moves upward) to accommodate
the new layers.

Cooling and Finishing: Once the printing is complete, the object may require
some post-processing, such as removing support structures (if used) or sanding
rough edges. The object is then allowed to cool and harden fully.

POWDER-BASED Selective Laser Sintering (SLS):

SLS is a 3D printing technique that combines additive manufacturing with
powerful lasers to fuse together finely ground material particles into a solid
structure.

Preparation: The first step in the procedure is to create a computerized three-

dimensional model of the item that has to be produced. With the use of
specialist software, this digital model is divided into tiny layers.

Material handling: A build platform is covered evenly with fine powder

material, such as metal powder, nylon powder, or polyamide powder. Each
layer usually has a thickness of tens to hundreds of micrometers.

Selective Sintering: Using a powerful laser to scan the object's cross-section, the
powdered material is fused or sinterbed selectively in accordance with the
current layer's shape, which is determined by the slicing.

Preparation: The process starts with the preparation of a digital 3D model of the
object to be manufactured. This digital model is sliced into thin layers using
specialized software.

Material Handling: Fine powder material, such as nylon, polyamide, or metal

powder, is spread uniformly across a build platform. The thickness of each layer
typically ranges from tens to hundreds of micrometers.
Selective Sintering: A high-powered laser scans the cross-section of the object,
selectively sintering or fusing the powdered material according to the shape of
the current layer as defined by the sliced digital model. The laser heats the
powder particles to a temperature just below their melting point, causing them
to fuse together and form a solid layer.

Layer-by-Layer Build: After sintering one layer, the build platform is lowered,
and a new layer of powder is spread on top. The laser then selectively sinters
this new layer onto the previous one. This process repeats layer by layer until
the entire object is formed.

Cooling and Post-Processing: Once the object is fully built, it is left to cool
within the powder bed. After cooling, the object may undergo additional post-
processing steps, such as removing excess powder, surface finishing, or heat
treatment, depending on the specific requirements of the application.

Laminated Object Manufacturing (LOM) (Solid based):

Laminated Object Manufacturing (LOM) is a type of additive manufacturing
process that builds 3D objects layer by layer using sheets or layers of material
bonded together. Unlike many other additive manufacturing methods that work
with liquid or powdered materials, LOM starts with sheets of material, typically
paper or plastic-coated paper, that are adhered together and cut into the desired
shape using a computer-controlled laser or blade.

Layering: LOM begins with a stack of thin sheets of material. These sheets are
typically adhesive-coated to facilitate bonding.

Cutting: A computer-controlled laser or knife cuts the outline of each layer

according to the shape of the object being manufactured. The excess material
that is not part of the object remains attached to the surrounding support
structure.
Bonding: After each layer is cut, it is bonded to the layer below using heat,
pressure, or adhesive. This bonding process creates a solid object one layer at a
time.

Repeat: Steps 2 and 3 are repeated layer by layer until the entire object is built
up.

Finishing: Once the object is complete, excess material is removed, and any
necessary finishing processes, such as sanding or painting, may be applied.

ADVANTAGES OF ADDITIVE MANUFACTURING

Additive manufacturing (AM), also known as 3D printing, offers numerous
advantages over traditional manufacturing methods. Here are some key
advantages:

1. Design Flexibility: AM enables the creation of highly complex geometries

that are difficult or impossible to achieve with traditional manufacturing
methods. This design freedom allows for the production of intricate and
customized parts tailored to specific needs.

2. Reduced Material Waste: Traditional manufacturing often involves

subtractive processes where material is removed from a block or sheet, leading
to significant waste. In contrast, AM builds objects layer by layer, minimizing
material waste and reducing environmental impact.

3. Cost-Effectiveness: While the initial investment in AM equipment may be

higher compared to traditional manufacturing machinery, AM can be more cost-
effective for low-volume production runs or customized parts. Additionally,
AM eliminates the need for tooling, reducing upfront costs and lead times.

4. Rapid Prototyping: One of the most significant advantages of AM is its

ability to rapidly produce prototypes for testing and iteration. AM allows for
quick design modifications without the need for expensive tooling changes,
accelerating the product development cycle.

5. On-Demand Production: AM enables on-demand production, allowing

manufacturers to produce parts as needed, reducing inventory costs and
minimizing supply chain logistics. This flexibility is particularly advantageous
for producing spare parts, personalized products, or small-batch production
runs.

6. Complex Assembly Consolidation: With AM, multiple parts can be

consolidated into a single, complex component, reducing the need for assembly
and potentially improving the overall performance of the final product. This
simplification of assembly can lead to cost savings and enhanced product
reliability.

7. Customization and Personalization: AM facilitates the production of

customized products tailored to individual preferences or specific requirements.
This capability is valuable in various industries, including healthcare (e.g.,
custom medical implants) and consumer goods (e.g., personalized accessories).

8. Supply Chain Resilience: AM can contribute to supply chain resilience by

decentralizing production and reducing reliance on overseas manufacturing
facilities. Localized production using AM technology can mitigate disruptions
caused by geopolitical tensions, natural disasters, or other unforeseen events.

9. Innovative Material Options: AM processes support a wide range of

materials, including metals, polymers, ceramics, and composites. Additionally,
advancements in material science are continually expanding the available
material options, enabling the production of parts with enhanced properties such
as strength, flexibility, or conductivity.

10. Accessibility and Democratization: The accessibility of AM technology is

increasing, with desktop-sized 3D printers becoming more affordable and user-
friendly. This democratization of manufacturing enables entrepreneurs,
hobbyists, and small businesses to innovate and bring their ideas to life without
the need for extensive resources or expertise.

Overall, additive manufacturing offers a myriad of advantages that revolutionize

the way products are designed, produced, and distributed, making it a valuable
tool for various industries seeking to innovate and stay competitive in today's
dynamic marketplace.