Additive manufacturing overview

Luis Escalona

Additive Manufacturing (AM)

What is AM ?

How it works

Defined by ASTM: F2792 12a as

the " process of joining materials to
make objects from 3D model data,
usually layer upon layer, as opposed
to subtractive manufacturing
methodologies, such as traditional
machining. (Leary et al, 2014).

Parts are made by adding material

in layers; each layer is a thin crosssection of the part derived from the
original CAD data. (Gibson et al,
2009).

A model, initially generated using a

(3D CAD) system, can be fabricated
directly without the need for
process planning. (Gibson et al,
2009).
Gibson I., Rosen D. W. and Stucker B., 2009. Additive Manufacturing Technologies. Rapid Prototyping to Direct Digital
Manufacturing. New York: Springer.
Leary M, Merli L, Torti F, Mazur M and Brandt M., 2014. Optimal topology for additive manufacture: A method for
enabling additive manufacture of support-free optimal structures. Materials and Design, 63, 678-690.

8 stages of the AM process

Conceptualization and CAD. Starts with 3D
CAD information for enclosed objects and
surface continuity.

Conversion to STL (STereoLithography).

Removal of any construction data, modeling
history, etc., and approximating the surfaces
of the model with a series of triangular facets.
Transfer to AM Machine and STL File
Manipulation. Verification of correctness,
manipulation of the part and (if required)
segmentation or merging of STL files.
Machine Setup. Setup adjustments according
to the machine or process.
Build. The sequence of layer control is
undertaken, using a height adjustable
platform, material deposition, and layer crosssection formation.
Removal and Cleanup. Part is either separated from
a build platform on which the part was produced or
removed from excess build material surrounding the
part. Supports (when used) are removed.

5
6

1
7
8

(Gibson et al, 2009)

Application. Parts are ready for use although
they may not behave according to standard
material specifications
Post-process. Refers to the (usually manual) stages of finishing the
parts for application purposes through: abrasive finishing (polishing
and sandpapering) or application of coatings

Gibson I., Rosen D. W. and Stucker B. , 2009. Additive Manufacturing Technologies. Rapid Prototyping to Direct Digital
Manufacturing. New York: Springer.

Additive Manufacturing process

Stages of production for a laser sintered removable partial denture: Dental

prosthesis directly after manufacturing, with support structures removed
and surface polished, after completion. Retrieved November 4, 2014 from
http://additivemanufacturing.com/

Additive manufacturing piece with support

structures. Retrieved November 4, 2014 from
http://flatrock.org.nz/

Additive Manufacturing techniques

Highest levels of technical
maturity (Muir et al, 2014)
Powder Bed (PB).
Direct Energy Deposition.
Wire-fed.

Powder bed AM techniques

demonstrate suitable levels of
process maturity. (Muir et al,
2014)
Its dominant techniques are:
Direct Metal Laser Sintering
(DMLS).
Electron beam melting (EBM).

Muir J, Toropov V and Querin O. , 2014. Rules, Precursors and Parametrization Methodologies for Topology Optimized
Structural Designs Realized Through Additive Manufacturing. 10th AIAA Multidisciplinary Design Optimization
Conference. Maryland: AIAA SciTech.

Additive Manufacturing techniques

DMLS

EBM

Low temperatures.

High temperatures.

Within an Ar filled chamber.

Energy is applied to the part slices
by 200 W or 400 W CO2 based
laser.

Within a vacuum, preheating

performed in-between each
applied layer using a defocused
EB prior to refocusing the beam
energy for the primary belt.

Muir J, Toropov V and Querin O. , 2014. Rules, Precursors and Parametrization Methodologies for Topology Optimized
Structural Designs Realized Through Additive Manufacturing. 10th AIAA Multidisciplinary Design Optimization
Conference. Maryland: AIAA SciTech, 2014.

Technical limitations

Fatigue performance.
Porosity.
Material microstructure.
Geometric features.

Factors affecting PB AM produced parts are:

Surface roughness (SR), resulting from energy overspill layer thickness,
powder size, energy properties and highly overhung angled surfaces.
Geometric distortion (GD).
Build economics (BE).

Muir J, Toropov V and Querin O., 2014. Rules, Precursors and Parametrization Methodologies for Topology Optimized
Structural Designs Realized Through Additive Manufacturing. 10th AIAA Multidisciplinary Design Optimization
Conference. Maryland: AIAA SciTech.

Technical limitations

Implantable titanium screw made with DMLS also

shows the rough surface (close-up), which is useful
for rapid bone bonding and growth. Retrieved
November 4, 2014 from
http://www.productionmachining.com/

Topology Optimization
Topology optimization methods solve a material distribution problem to
generate an optimal topology.
It is usual for each finite element within the design domain to be defined
as a design variable, allowing a variation in density (homogenization,
Solid Isotropic Microstructure with Penalization (SIMP)) or void-solid
(bidirectional evolutionary structural optimization (BESO)) . (Bracket et
al, 2011).

Other methods exist such as genetic algorithms and level set methods
but these are still in their infancy with regards to their suitability to real
life problems and so are not discussed here. (Bracket et al, 2011).

Brackett D., Ashcroft I and Hague R., 2011. Topology optimization for additive manufacturing. International Solid
Freeform Fabrication Symposium, August 8-10, Austin, TX.

Topology Optimization

Workflow for topology optimization for AM, with sub-flowchart for the geometry modification stage.
(Bracket et al, 2011).

Brackett D., Ashcroft I and Hague R., 2011. Topology optimization for additive manufacturing. International Solid
Freeform Fabrication Symposium, August 8-10, Austin, TX.

Topology Optimization

Remeshing an STL to a mesh of better quality for FEA. (Bracket et al, 2011).

Workflow for retaining geometric associativity for remeshed regions. (Bracket et al, 2011).

Brackett D., Ashcroft I and Hague R., 2011. Topology optimization for additive manufacturing. International Solid
Freeform Fabrication Symposium, August 8-10, Austin, TX.

Topology Optimization works, 1

Finite element based topology optimization (TO) is a powerful method of
structural optimization, however the results obtained tend to be dependent
on the algorithm used, the algorithm parameters and the finite element
mesh.
Aremu et al discuss these issues as it relates to the SIMP and BESO
algorithms.
Though BESO and SIMP attains optimal topologies efficiently, these
topologies are often local since the TO is constrained by starting design, finite
element mesh and parametric values. These less complex optima are suitable
for traditional manufacturing; AMs ability to make complex parts allows the
production of truly optimal parts. Hence this algorithms needs to be
improved for AM.
These improvement might cause the TO to efficiently attain highly complex
topologies with improved performance. These topologies can be made via
AM.
Aremu, A., I. Ashcroft, R. Hague, R. Wildman, and C. Tuck., 2010. Suitability of SIMP and BESO Topology Optimization
Algorithms for Additive Manufacturing. Tech. Loughborough.

Topology Optimization works, 2

Krol eta al (2013) considered that a virtual process design prior to the
building phase is an opportunity to enhance the process efficiency of metalbased, additive processes.
Methods and procedures for the identification, categorization and
prioritization of influencing parameters and their interdependencies
amongst each other are shown for the target figure "dimensional accuracy"
using the alloy AlSi12.
The results of these investigations are summarized in a process-specific
prioritization and correlation matrix.
For a sensitivity sampling, a full factorial experimental design is elaborated.
With the application of three states for every parameter, 81 simulation sets
were calculated, evaluated and compared.
Krol T.A., Seidel C., Zaeh M.F., 2013. Prioritization of process parameters for an efficient optimisation of additive
manufacturing by means of a finite element method. 8th CIRP Conference on Intelligent Computation in
Manufacturing Engineering

Topology Optimization works, 2

After qualitative selection of factors and quantitative prioritization
and categorization.

The support structure exhibits a significant influence on the focused target figure
"dimensional accuracy". Furthermore a high correlation between the support
definition and the scanning strategy of overhanging part areas (above support
sections) is existent.
Krol T.A., Seidel C., Zaeh M.F., 2013. Prioritization of process parameters for an efficient optimisation of additive
manufacturing by means of a finite element method. 8th CIRP Conference on Intelligent Computation in
Manufacturing Engineering

Topology Optimization works, 3

Gardan and Schneider aim to present a methodology and a tool, which allow
the use of topological optimization for the preparation of model for RP and
AM.
The majority of research mainly focused on the implementation of new forms
(honeycomb lattice etc.) but uses little power topology optimization in
numerical simulation that allows automatical modelling of the shape
automatically. Knowledge management is however necessary to obtain
innovative form in the trade con-text. It is important to note the necessity to
manage the drainage system of the support part.
As seen previously, using the SIMP method for topological optimization
dedicated to rapid prototyping seems to be interesting. It requires an
adaptation of modelling process and thus some work on knowledge
modelling and its numerical integration. A methodology of application is
also required.

Gardan N and Schneider A., 2014. Topological optimization of internal patterns and support in
additivemanufacturing. Journal of Manufacturing Systems.

Topology Optimization works, 3

Through the whole process, one fact is taken into account: it is necessary to
evacuate support material at the end of the AM process
The researchers developed DOE (Design of Experiment) for different tests: test of
the laser temperature impact, test of the thickness and height allowed (with
cleaning process), test of the manufacturing orientation, test of the plate
placement etc.

View of the interior of the hip after the optimization

Gardan N and Schneider A., 2014. Topological optimization of internal patterns and support in
additivemanufacturing. Journal of Manufacturing Systems.

Topology Optimization works, 4

Leary et al present an automated method to modify topologically optimal
geometries as required to enable support-free manufacture. The SIMP
topology optimization method is applied.
This work focuses on the Fused Deposition Modelling (FDM) method,
whereby a component is manufactured with an extruded polymer filament.
When surfaces are detected to lie outside the robust zone, a dedicated
support material is used to ensure manufacturability. The use of support
material significantly increases the number of geometries that are feasible
with the FDM process.
This research aims to identify geometries that are not within the robust zone,
and to modify this infeasible geometry as required to ensure support-free
manufacturability.
Leary M, Merli L, Torti F, Mazur M and Brandt M., 2014. Optimal topology for additive manufacture: A method for
enabling additive manufacture of support-free optimal structures. Materials and Design, 63, 678-690.

Topology Optimization works, 4

Although the method was applied to polymeric additive manufacture, initial
analysis indicates that the method is beneficial to metallic systems as it acts
to reduce heat transfer resistance, thereby reducing peak and average
temperatures.

Comparison of results with:

Machine support, Optimal support,
No support

Leary M, Merli L, Torti F, Mazur M and Brandt M., 2014. Optimal topology for additive manufacture: A method for
enabling additive manufacture of support-free optimal structures. Materials and Design, 63, 678-690.

Topology Optimization works, 5

Darling et al (1997) described a new way to design and fabricate compliant
micromechanisms and material structures with negative Poisson's ratio (NPR)
by means of a numerical topology optimization method.

Material with Poisson's ratio -0.8 obtained from a ground structure

with 40 by 40 and vertical symmetry enforcement

With the development of computers, it is possible to proceed with detailed

design. Therefore the use of 3D printers allows the manufacture of 3D blocks
resembling the aforementioned behavior as Sigmund (2014) presents.
Darling U., Sigmund O and Bouwstra S., 1997. Design and Fabrication of Compliant Micromechanisms and
Structures with Negative Poissons Ratio. Journal of Microelectromechanical Systems, No.6, Vol. 2, 99.

Topology Optimization works, 6

Sigmund and Torquato (1997) show how composites with extremal or unusual
thermal expansion coefficients can be designed using three-phase (two different
material phases and void) topology optimization methods.

Optimal microstructures for minimization of effective thermal strain coefficient.

Extreme thermal expansion behavior can be obtained but at the cost of a low bulk
modulus. Therefore, there is a tradeoff between extremizing thermal strain
coefficients on the one hand and ending up with a stiff material on the other.
In addition, Sigmund (2014) presents the use of topology optimization on 3D
blocks to resemble the aforementioned behavior.
Sigmund O. and Torquato S., 1997. Design of materials with extreme thermal expansion using a three-phase
topology optimization method. Journal of Mechanics and Physics of Solids, Vol. 45, No. 6. 1037-1067.

Summary
Additive Manufacturing opens new opportunities for topology
optimization since it is possible to overcome the barriers of
manufacturing complexity.
Optimization in Additive Manufacturing is focused on the designed part
and its supporting structure since the latest plays an important role.
The use of Additive Manufacturing demands the adjustment of the
design algorithm for SIMP and BESO.

Consideration of variables from different stages of the Additive

Manufacturing process can be fundamental for good results after
Topology Optimization is applied.