3D Printing and Design (Advance)

UNIT-4

Syllabus

Unit-4.0 Powder based 3D Printing Processes

4.1 Powder fusion mechanism.

4.2 Principle and working of Selective Laser Sintering (SLS) process.

4.3 SLS based 3D printers.

4.4 Laser Engineering Net Shaping process.

4.5 Electron Beam Melting.

4.6 Binder Jet 3D Printing.

4.7 Materials and Process parameters for SLS based 3D printing processes.

4.8 Cost estimation of SLS based 3D printed component.

Unit-4.0 Powder based 3D Printing Processes

Powder-based 3D printing processes, also known as powder bed fusion or powder bed
additive manufacturing, are a group of additive manufacturing technologies that use
powdered materials as the base material for creating three-dimensional objects. These
processes involve selectively fusing or solidifying layers of powder material to build up the
final object.
4.1 Powder fusion mechanism.

The powder fusion mechanism refers to the process by which powdered materials are
selectively fused or melted together in powder-based 3D printing processes. This
mechanism is the fundamental principle underlying various techniques such as Selective
Laser Sintering (SLS), Selective Laser Melting (SLM), Electron Beam Melting (EBM), and
similar processes.

The general steps involved in the powder fusion mechanism are as follows:

1. Layer Preparation: The build platform is coated with a thin layer of powdered
material. This material can be metal, plastic, ceramic, or composite powders,
depending on the specific process and application. The layer thickness typically
ranges from tens to hundreds of micrometers.

2. Energy Application: A high-energy source, such as a laser or an electron beam, is

precisely directed onto the powder layer. The energy source provides the necessary
heat to locally fuse or melt the powder particles. The energy source's intensity,
duration, and focus are carefully controlled to ensure that only the desired areas are
affected.

3. Melting or Sintering: The energy from the laser or electron beam causes the powder
particles within the target area to heat up rapidly. In the case of SLS, the powder
particles experience controlled heating to the point of sintering, where they partially
melt and fuse together at their contact points, forming a solidified layer. In the case
of SLM and EBM, the powder particles are heated to their melting point, resulting in
full melting and fusion.

4. Solidification: After the energy source has passed over a specific area, it is turned off
or redirected to another location. The fused or melted powder layer then begins to
solidify as the heat dissipates. The solidified layer provides a foundation for the
subsequent layer to be built upon.

5. Layer-by-Layer Building: The process is repeated for each layer, with the build
platform being lowered or the energy source and scanning mechanism adjusted to
account for the newly solidified layer. This layer-by-layer approach gradually builds
up the final 3D object.

6. Cooling and Solidification: As the printing progresses, the heat from the energy
source dissipates, and the fused layers cool and solidify further. This ensures that the
entire object retains its structural integrity and desired properties.

The powder fusion mechanism allows for the creation of complex geometries and functional
parts with a wide range of materials, including metals, ceramics, polymers, and composites.
The controlled application of heat through lasers or electron beams ensures precise control
over the melting, sintering, and fusion processes, enabling the production of high-quality
parts with specific mechanical, thermal, and chemical properties. However, post-processing
steps such as removing excess powder, support structure removal, and surface finishing are
often necessary to achieve the final desired result.

4.2 Principle and working of Selective LaserSintering (SLS) process.

Selective Laser Sintering (SLS) is a powder-based additive manufacturing process that uses a
high-powered laser to selectively fuse powdered materials, such as plastics, metals,
ceramics, and composites, to create three-dimensional objects.

The SLS process offers advantages like the ability to create intricate and complex geometries
without the need for support structures, versatility in material selection, and the potential
to produce functional parts. However, it also requires careful handling of powder materials,
proper calibration of the laser and scanning system, and attention to post-processing steps
for achieving the desired final quality.

Here's a breakdown of the principle and working of the SLS process:

Principle of SLS: The SLS process is based on the principle of selective heating and fusion of
powdered material. A laser is used to scan and selectively fuse a thin layer of powdered
material, and then subsequent layers are built upon the previously fused layer. The process
is controlled by a digital model, which guides the laser's movements and ensures accurate
layer-by-layer fabrication.
Working of SLS:

1. Preparation: The process begins with the preparation of the build platform. A layer
of powdered material is spread evenly over the build platform using a roller or other
spreading mechanisms.

2. Laser Scanning: The 3D model of the desired object is sliced into thin cross-sectional
layers using specialized software. The data from these slices guides the movement of
the laser. The build platform is then lowered by the thickness of one layer, and the
first layer of the object is ready for printing.

3. Selective Fusion: A high-powered CO2 laser is directed by a scanning system to trace

the outline and fill the interior of the current layer of the object to be printed. The
laser heats the powdered material to just below its melting point, causing the
particles to fuse together. The unfused powder surrounding the fused areas acts as
temporary support, allowing complex geometries to be built without the need for
additional support structures.

4. Cooling and Solidification: As the laser moves over the powder, the fused areas cool
down rapidly and solidify, forming a solid layer. The unfused powder acts as a
thermal buffer, preventing excessive heat from affecting the surrounding material.

5. Layer Addition: After the current layer is sintered and solidified, the build platform is
lowered by the thickness of the next layer, and a new layer of powdered material is
spread over the previously solidified layer. The process repeats: the laser scans the
new layer, selectively fusing the material as per the digital model's instructions.

6. Build Completion: The layer-by-layer fusion process continues until the entire 3D
object is built within the powder bed. The unprocessed powder surrounding the
printed object acts as a natural support structure during the build process.

7. Cooling and Cooling Down: Once the printing is complete, the entire build chamber
is allowed to cool down. The printed object is then carefully removed from the
unprocessed powder bed. Excess powder is typically removed using brushing,
blowing, or other methods.

8. Post-Processing: The printed object might undergo further post-processing steps,

such as surface finishing, cleaning, and heat treatment, depending on the material
and desired properties of the final part.
4.3 SLS based 3D printers.

Formlabs Fuse 1: This is a desktop SLS printer that is known for

its ease of use and high quality prints. It is capable of printing
with a variety of materials, including nylon, PA12, and glass-
filled nylon.

Sinterit Lisa X: This is another desktop SLS printer that is known for its fast
print speeds and large build volume. It is capable of printing with a variety
of materials, including PA12, TPU, and PC.

EOS P 396 DMP: This is an industrial SLS printer that is capable of

printing large and complex parts. It is used in a variety of industries,
including automotive, aerospace, and medical.

HP Jet Fusion 5200 Series: This printer combines MJF and SLS
capabilities, offering high-speed and precise printing for industrial
applications.

Concept Laser Mlab Cusing 2.0: This is another industrial SLS

printer that is known for its high precision and accuracy. It is used
to print prototypes and production parts for a variety of industries.

4.4 Laser Engineering Net Shaping process.

Laser Engineered Net Shaping (LENS) is a

metal additive manufacturing (AM) process
that uses a high-power laser to melt metal
powder and deposit it layer by layer to
create a solid object. The process is similar
to selective laser melting (SLM), but LENS
uses a coaxial powder delivery system,
which means that the powder is delivered
directly to the laser beam. This allows for
more precise control of the melt pool and results in better quality parts.

It's used primarily for metal 3D printing and repairing or adding material to existing
components.

The LENS process is typically used to create small to medium-sized parts with complex
geometries. It is well-suited for applications where high strength and precision are required,
such as in the aerospace, medical, and automotive industries.

LENS technology is used in various industries, including aerospace, automotive, and medical,
for applications such as rapid prototyping, manufacturing complex components, and
repairing or adding material to existing parts. It offers advantages like excellent material
utilization, high deposition rates, and the ability to create near-net-shape components.

Principle of LENS: The LENS process involves the precise deposition of metal powder, which
is simultaneously melted by a high-power laser. This molten material forms a small pool or
melt pool on the substrate or the previous layer. As the laser moves, it fuses the deposited
material with the underlying layers, creating a solid, three-dimensional object. LENS is highly
versatile and can be used with various metals and alloys.

Working of LENS:

1. Preparation: The process begins with the preparation of a computer-aided design

(CAD) model of the desired object. This digital model is sliced into thin cross-
sectional layers using specialized software.

2. Material Delivery: Metal powder is continuously delivered to the deposition head

through a nozzle or feed tube. The nozzle is positioned very close to the substrate or
the previously deposited layer.

3. Laser Deposition: A high-power laser, typically a CO2 or fiber laser, is directed

through an optics system to precisely focus the beam onto the material deposition
point. The laser's energy melts the metal powder at the deposition point.

4. Deposition and Melting: As the laser moves according to the instructions from the
CAD model, it melts the metal powder, forming a small melt pool. Simultaneously,
the deposition head moves to lay down more powder, which is fused with the
underlying layer. This process is repeated layer by layer, allowing the object to
gradually take shape.

5. Cooling and Solidification: Once each layer is deposited and melted, it rapidly cools
and solidifies. The subsequent layers adhere to the solidified material below,
building up the 3D object.
 6. In-Process Monitoring: Some LENS systems include sensors and cameras for
monitoring the process in real-time. This helps ensure accurate deposition and
quality control.

7. Multi-Material Printing: Some advanced LENS systems allow for the deposition of
multiple materials or alloys in a single build, enabling the creation of gradient
materials or multi-material parts.

8. Finish and Post-Processing: After the printing is complete, the final object may
require post-processing steps, such as machining, heat treatment, or surface
finishing, to achieve the desired specifications and surface quality.

Here are the steps involved in the LENS process:

1. A CAD model of the part is created.

2. The part is sliced into thin layers.

3. The build platform is loaded with a substrate material, such as a metal plate.

4. The powder is delivered to the laser beam.

5. The laser beam melts the powder and fuses it to the substrate.

6. The build platform is lowered and the process repeats until the part is complete.

The LENS process has a number of advantages over other AM processes, including:

 The ability to create parts with complex geometries

 The ability to use a wide variety of metal materials

 The ability to achieve high strength and precision in the parts

 The ability to produce parts with minimal post-processing

The LENS process also has some disadvantages, including:

 The high cost of the equipment

 The time-consuming process of creating CAD models

 The need for skilled operators

4.5 Electron Beam Melting.

Electron Beam Melting (EBM) is an

advanced additive manufacturing (AM)
process that uses a high-energy electron
beam to melt and fuse metal powder,
layer by layer, to create three-
dimensional objects. EBM is particularly
known for its capability to produce
complex and high-performance metal
parts with good mechanical properties.

EBM technology is often used in

aerospace, medical, and other industries that require high-quality metal parts with complex
geometries and excellent mechanical properties. It offers advantages like minimal residual
stress due to the high-speed cooling process, the ability to work with a wide range of metal
alloys, and the potential for high-density, fully dense parts. However, EBM machines require
high vacuum conditions to prevent electron scattering and interference, which adds
complexity to the manufacturing environment.

Here's an overview of the Electron Beam Melting process:

Principle of Electron Beam Melting: EBM operates on the principle of localized melting and
solidification of metal powder using an electron beam. The focused electron beam is
capable of rapidly heating the metal powder to a temperature at which it melts and then
solidifies upon cooling.

Working of Electron Beam Melting:

1. Preparation: The process starts with the preparation of a digital 3D model using
computer-aided design (CAD) software. The digital model is then sliced into thin
cross-sectional layers using specialized software.

2. Powder Layer Application: A thin layer of metal powder is spread uniformly onto the
build platform. The chosen metal powder may include various alloys, each selected
based on the desired properties of the final part.

3. Electron Beam Scanning: An electron beam gun directs a high-energy electron beam
onto the powder layer according to the instructions from the sliced CAD model. The
electron beam scans the powder layer in a precise pattern, selectively melting the
powder particles at the chosen points.

4. Melting and Solidification: When the high-energy electron beam hits the powder
particles, it transfers its energy to the particles, causing them to melt almost
 instantaneously. As the beam moves, the melted material solidifies quickly due to
rapid cooling. This creates a solid layer that adheres to the underlying powder bed.

5. Layer-by-Layer Building: After one layer is melted and solidified, the build platform
is lowered, and a new layer of metal powder is spread over the previous layer. The
electron beam scans the new layer, fusing it with the underlying layers. This process
is repeated layer by layer until the entire part is built.

6. Cooling and Post-Processing: Once the build is complete, the part and surrounding
powder bed are allowed to cool down. After cooling, the part is removed from the
unprocessed powder, and any excess powder is removed using brushing or other
techniques. The final part may undergo additional post-processing steps, such as
heat treatment, machining, or surface finishing, to achieve the desired specifications.

4.6 Binder Jet 3D Printing.

Binder Jetting is an additive manufacturing (AM) process that creates three-dimensional

objects by selectively depositing a liquid binding agent onto a powdered material bed. This
process is particularly useful for producing parts from a variety of powdered materials,
including metals, ceramics, and polymers. Binder Jetting is known for its speed, versatility,
and ability to create complex geometries.
Binder Jetting is known for its speed and scalability, making it suitable for producing
prototypes, functional parts, and even large-scale objects. The process is often used for
applications such as creating metal parts, ceramic components, sand molds for casting, and
more. However, the final parts may require additional treatments to achieve desired
mechanical properties and surface finishes, and some geometries may need to be carefully
designed to avoid collapse during the printing process.

Here's an overview of the Binder Jetting process:

Principle of Binder Jetting: Binder Jetting operates on the principle of selectively binding
powdered material particles together using a liquid binding agent. The process involves the
deposition of the binding agent onto the powder bed in precise patterns according to the
cross-sectional shape of the object being printed. Once a layer is complete, a new layer of
powder is spread, and the process is repeated layer by layer to build the final object.

Working of Binder Jetting:

1. Powder Bed Preparation: The process begins with the spread of a thin layer of
powdered material over the build platform. The powder is typically spread using a
roller mechanism to ensure uniform thickness.

2. Binder Application: A print head deposits a liquid binding agent onto the powdered
layer in a controlled manner. The binding agent is selectively deposited in the areas
where material fusion is required based on the digital design data.

3. Layer-by-Layer Building: After the binder is applied, a new layer of powder is spread
over the previous layer. The binder application and powder spreading process is
repeated for each layer, building up the object vertically. The binder acts like a glue,
binding the powder particles together in the shape of the desired cross-section.

4. Post-Binding Treatment: After each layer, the binder may be cured using heat, UV
light, or other means to enhance its bonding properties and solidify the printed
layer.

5. Support Material Deposition (Optional): If the object being printed has overhangs or
complex geometries, a secondary material, often referred to as support material,
may be deposited alongside the binder to provide temporary structural support. This
support material can be later removed after printing is complete.

6. Cooling and Finalization: Once the printing is finished, the entire object is allowed to
cool. Excess, unbonded powder can be reused for subsequent prints. The printed
object is carefully removed from the unbound powder bed.
 7. Post-Processing: The printed object may undergo additional post-processing steps,
such as curing, infiltration with other materials for enhanced strength or properties,
and surface finishing.

4.7 Materials and Process parameters for SLS based 3D printing processes.

Selective Laser Sintering (SLS) is a versatile 3D printing process that can work with various
materials, including polymers, metals, ceramics, and composites. The choice of materials
and process parameters depends on the specific application and desired characteristics of
the final printed parts. Here's a general overview of materials and process parameters for
SLS-based 3D printing:

Materials:

1. Polymers: SLS is commonly used for printing with thermoplastic polymers. Some
commonly used polymer materials include:

 Nylon (PA, PA12, PA11): Known for its durability and flexibility, nylon is one of
the most popular choices for SLS printing.

 TPU (Thermoplastic Polyurethane): Used for producing flexible and elastic

parts.

 PEEK (Polyether Ether Ketone): Suitable for high-temperature and chemical-

resistant applications.

 PPS (Polyphenylene Sulfide): Offers excellent mechanical and thermal

properties.

 TPE (Thermoplastic Elastomer): Combines the properties of rubber and

plastic.

2. Metals:

 Aluminum, titanium, stainless steel, and various other metal alloys can be
used in SLS-based metal printing.

 Metal powders must have good flowability, consistent particle size

distribution, and appropriate thermal properties for successful SLS
processing.

3. Ceramics and Composites:

 Ceramics like alumina, zirconia, and glass-filled materials can be used for
specialized applications.
  Composites, such as carbon fiber-reinforced materials, can offer enhanced
mechanical properties.

Process Parameters:

1. Laser Power: The power of the laser used to sinter or melt the powder affects the
speed and quality of the process. Higher power can result in faster melting/sintering
but might also affect heat distribution and part quality.

2. Scanning Speed: The speed at which the laser scans across the powder bed affects
the time taken to complete a layer. Balancing speed with quality is crucial.

3. Layer Thickness: The thickness of each printed layer affects the resolution of the
final part. Thinner layers can provide finer details but might also increase printing
time.

4. Powder Bed Temperature: The temperature of the powder bed influences the
sintering/melting process. It's essential for maintaining consistent powder flow and
proper adhesion.

5. Build Chamber Temperature: The temperature inside the build chamber can impact
material properties and part quality. For example, it might be controlled to avoid
warping or maintain uniform properties.

6. Hatch Spacing: The distance between each laser pass, also known as the hatch
spacing, affects surface finish. Smaller hatch spacing can result in smoother surfaces
but longer printing times.

7. Powder Type and Properties: Different materials have varying particle sizes, shapes,
and thermal properties. These properties influence how the powder absorbs and
conducts heat during the process.

8. Scan Strategy: The way the laser scans the powder bed (e.g., contour, hatching,
island) affects part accuracy, build speed, and heat distribution.

9. Part Orientation and Supports: The orientation of the part on the build platform can
influence thermal stresses and warping. Support structures may be needed for
overhangs and complex geometries.

10. Cooling and Cooling Rate: Controlled cooling can prevent warping and improve part
quality. Gradual cooling can help reduce residual stresses in the printed part.
4.8 Cost estimation of SLS based 3D printed component.

Estimating the cost of an SLS-based 3D printed component involves considering various

factors, including material cost, machine time, labor, post-processing, and overhead. The
actual cost can vary widely depending on factors such as the size and complexity of the part,
the chosen material, the 3D printing service provider, and the specific requirements of the
project. Here's a general outline of the factors to consider when estimating the cost of an
SLS 3D printed component:

1. Material Cost:

 The cost of the powdered material used for SLS printing is a significant factor.
Different materials have varying costs per unit weight.

 Some materials, especially metal powders, can be considerably more

expensive than polymers.

2. Machine Time and Build Volume:

 The time required to complete the 3D printing process, including the printing
of each layer and the overall build time, affects the cost.

 Larger parts or parts with higher layer counts will require more machine time
and, therefore, may cost more.

3. Labor Costs:

 Labor costs include the time and expertise required for tasks such as part
setup, post-processing, and quality control.

 Complex parts or parts requiring manual support removal may increase labor
costs.

4. Post-Processing:

 Some SLS parts require post-processing steps like support removal, heat
treatment, surface finishing, and inspection.

 These steps contribute to the overall cost of the part.

5. Machine and Facility Overhead:

 The 3D printing service provider's overhead costs, including machine

maintenance, facility rent, and utilities, are factored into the cost.

6. Quantity and Batch Size:

  Printing multiple parts in a single build can lead to cost savings per part due
to efficient use of machine time and materials.

7. Material Waste:

 Some powder-based processes generate excess, unused powder that can be

reused for subsequent prints. The cost of virgin and recycled powder can
impact the overall cost.

8. Quality and Tolerance Requirements:

 Parts with high precision and tight tolerance requirements might require
more careful setup, monitoring, and additional post-processing steps, which
can increase the cost.

9. Part Complexity and Design:

 Intricate and complex geometries may require additional printing time,

material usage, and post-processing, affecting the cost.

10. Shipping and Handling:

 Shipping and handling costs should be considered if the parts need to be

shipped to the customer or a different location.

To estimate the cost of an SLS 3D printed component accurately, it's recommended to work
with a 3D printing service provider or use cost estimation tools provided by software
platforms. Many service providers offer online quoting tools that consider various
parameters to provide an estimated cost based on the provided part specifications. Keep in
mind that the actual cost may vary from the estimate due to specific project considerations
and negotiations with the service provider.

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