TYPES OF MANUFACTURING PROCESSES-

1.
2.
3.
4.

FORMING
JOINING PROCESSES

REMOVAL PROCESSES
ADDITIVE MANUFACTURING

You want to make a sphere...

The really old way: Take a block of material and carve it out

The more modern way:

Generate 3D model
Generate CNC
program
Machine away
unwanted material
If possible, recycle
waste

* Generate a 3D model
* Software slices the 3D model into thin
slices

* Machine builds it layer by layer

Advantages:
Process is Independent of Part Feature
No Blanks are Requires
Tool less process
Easily Automation Possible

*Video

1)STEREOLITHOGRAPHY
Thin layers of UV sensitive liquid polymers are
solidified through the use of a laser.

Stereo lithography is a photo polymerisation process.

Three main photopolymer systems used are acrylate ,
epoxy and vinyl ether.

Layer thickness-Each layer is 0.076 mm to 0.50 mm (0.003 in

to 0.020 in.) thick
Scanning time is 500-25000 mm/s.

Part Built Time

Time to complete a single layer-

Ai
Ti
Td
vD
where Ti = time to complete layer i; Ai = area of
layer i; v = average scanning speed of the laser beam
at the surface; D = diameter of the spot size,
assumed circular; and Td = delay time between layers
to reposition the worktable

Total Time
Once the Ti values have been determined for all layers,
then the build cycle time is:

where Tc = STL build cycle time; and nl = number of layers

used to approximate the part
Time to build a part ranges from one hour for small parts
of simple geometry up to several dozen hours for complex
parts

Benefits and downsides

Benefits
No milling or masking steps needed.

Can be highly accurate

Only one material needed for build and support

Downsides
Requires post curing of material

Long term curing can lead to warping

Can have brittle parts with a tacky surface

Support structures are often needed

Material is toxic and light sensitive

Heated thermoplastics are extruded through nozzles ,

extruded material hardens as it cools.

Benefits
Can use standard engineering thermoplastics (ABS)

Can use multiple materials (One for bulid & support)

Can produce water tight parts

Parts are hardened very quickly

Downsides
Poor layer uniformity

Delamination of extruded layers can be problematic

Parts can have a rather coarse surface finish

Molten/liquid plastics printed along with wax support

structure.

Lasers used to selectively sinter/fuse layers of powdered

materials.

SLA- Excellent surface finish suitable for presentation,

master models and light functional testing.
FDM- Good combination of strength and surface finish at
affordable price and lead time.
3DP- Suitable for general purpose parts for initial design
stage with a quick delivery
SLS- Range of materials available, soft like rubber to
strong like metal. SLS Nylon suitable for snap and living
hinge features

Architecture and Design

There is a quote in AM-

IF U CAN DRAW IT WE CAN PRINT IT

We are pushing our limits . Manufacturing is not the
barrier to the entry , actually the design is the
barrier to the entry.

THATS THE POWER OF TECHNOLOGY

And it marks the beginning of next industrial
revolution.

Jane Chu, Sarah Engelbrecht, Gregory Graf, David W. Rosen, (2010) "A
comparison of synthesis methods for cellular structures with application to
additive manufacturing", Rapid Prototyping Journal, Vol. 16 Iss: 4, pp.275 283
Francis J. Quail, Thomas Scanlon and Matthew Strickland(2010) Development
of a regenerative pump impeller using rapid manufacturing techniques ,Rapid
Prototyping Journal Volume 16 Number 5 2010 pp 337344
Tomaz Brajlih, Bogdan Valentan, Joze Balic, Igor Drstvensek, (2011) "Speed and
accuracy evaluation of additive manufacturing machines", Rapid Prototyping
Journal, Vol. 17 Iss: 1, pp.64 75
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