Additive manufacturing 3D printing

Antonio Romero Calero

ABSTRACT
The aim of the present report is to provide a general overview about the main process of
additive manufacturing studied in Lappeenranta University of Technology Summer School
Course. The survey includes a short explanation of fused deposition modeling and powder
bed fusion. Then, advantages and disadvantages of theses process are pointed out in order
to know the strengths and weaknesses of both techniques.
In addition, a constant challenge in conducting the course was the implementation of
seminar group work. For this reason, we worked in group and we had to choose, design
and develop an idea. Based on this, different phases of the project are briefly summarized.
Besides, the reasons are given explaining why certain manufacturing method is used and
how it can be improved the different aspects of the project.
Finally, the report puts forward a short conclusion of seminar group work and includes a
reflection about the potential of additive manufacturing technologies.

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TABLE OF CONTENTS

1. INTRODUCTION
1.1. Background..... 4
1.2. Fused deposition modeling (FDM).. 5
1.3. Powder bed fusion (PBF)......... 7
2. METHODS
2.1. Introduction of seminar work model 12
2.2. Introduction of application area of seminar work model......... 13
2.3. Description of design process of seminar work introduce... 13
2.4. Discussion of selected manufacturing method. 16
3. CONCLUSIONS
3.1. Conclusions of seminar work... 17
3.2. Conclusions of literature review... 17

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1. INTRODUCTION

1.1. BACKGROUND
Additive Manufacturing (AM) is a process by which it can build 3D parts of any material
like powder, liquid, plastic, etc by adding material layer by layer. This term AM includes
different technologies like 3D Printing, Direct Digital Manufacturing (DDM), Rapid
Prototyping
3D printing is the technology focused on building objects by 3D solid part using some
printer technology. 3D printing can generate a three dimensional object o some of them by
any manufacturing process. For that, we need to follow a specific process. Firstly, we start
with an idea of what we want to do. Then we have to design our product by using 3D
software, take for instance Solid Work. Once the product is design, we convert the 3D
solid model into 3D STL model. A STL file is a net of triangles without bearing in mind
the colour, material, texture or other features. Only surface geometry is relevant. STL is the
abbreviation for STereoLithography. Given that 3D printers build the model layer by
layer, the STL file has to be sliced using specialist software. This software can be free as
CURA or similar or it is usually provided with the printer. Using this software you can
choose among different parameters in order to get the part as you like. After machine set
up, we can build the product.

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This technology could be considered as a new industrial revolution owing to several
advantages. Take for instance, designers can draw anything without limitations, therefore
they can create complex internal and external part. In this way, they can improve their
designs by using less material and cutting costs. Besides, prototypes can be elaborated in a
shorter amount of time and in small quantities. For these and many other reasons, Additive
Manufacturing is much better than traditional subtractive manufacturing methods base on
removing material like milling.
AM process can be classified in two technologies:
- Fused deposition modeling (FDM)
- Powder bed fusion (PBD)

1.2. FUSED DEPOSITION MODELING (FDM)

The fused deposition modeling technique consists of extruding material such as
thermoplastics, elastomers, pellets, powder or filament on a flat base, layer by layer. The
material is initially in solid state and stored in rolls, melts and is expelled by the nozzle in
small threads. This is the most common technique for 3D printing for home users.
FDM is used for many different purposes and industries such as medical devices,
aerospace, automotive and fashion.

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The main advantages of FDM are:
- Accuracy, we can get pieces with high precision.

- A wide range of material and colour.

- Without design restrictions.

- Fast printing speed.

- Cheap. We can produce part cheaper than others process.
It has some disadvantages too:
- Support structures can be required and must be removed.

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 - Size depends on the area of the printer.
- Some features of the parts need to be improved such as surfaces, holes and threads.

- Large amounts of pieces are unworkable.

1.3. POWDER BED FUSION (PBF)

Powder bed fusion is based on a laser or electron beam used to solidify powder material
layer by layer. It can be used polymers, metals and ceramics. You can see the process in
the following figure. At the beginning, the first powder layer is spread around the work
area. Then, powder bed layer is fused by using energy. Afterward the building platform
lowers and a new layer is spread around the work area. This process is repeated again and
again until finishing the solid part.

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There are similar PBF processes which use different names:
- DMLS. Direct metal laser sintering
- LS.- Laser sintering
- SLS.- Selective laser sintering
- EBM.- Electron beam melting
- Laser Cusing
- SLM.- Selective laser melting
- Laser forming
- Others
Powder bed fusion technology has remarkable advantages:
- Excellent material properties, such as metals, ceramics and polymers.
- Expensive tools are not necessary.

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- Production costs are reduced.

- Complex structures without limitations.

- High precision

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 - Reduces assembly requirements.

- Cooling channels are possible.

However, this technique has its drawbacks too:

- Porosity. If we want to improve the features we will need to post-process the parts.

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- Support structures are necessary in some cases.

- Necessary machining to remove the platform

- The accuracy depends on the powder particles size.
- Friction of the powder could create some flaws.

- Surface roughness need to be optimized.

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2. METHODS

2.1. INTRODUCTION OF SEMINAR WORK MODEL

After a day to discuss about innovative idea to be attractive for all, group 1 managed to
reach agreement. We decided to develop a new product with commercial potential,
innovative value and potential to develop further. In this way, we were studying different
options such as a customized watch or an optimizing weight and structure of machine part.
Although finally, we all agreed on drawing up a join which it could be used to easily
assemble customized tables.

The idea is based on the current trend of doing it by yourself. The emergent industry 4.0
allows us to get tailor-made solutions which guarantee customer satisfaction. This is the
main aim of the idea and the place where it emerges.

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 2.2. INTRODUCTION OF APPLICATION AREA OF SEMINAR WORK MODEL
The main advantage of our idea is that everyone can easily build smart tables without any
dimensional restrictions. Therefore, our product can be used both in home and commercial
usage. What is more, it could be customize with logos and text for brands. Also different
coloring is possible according to your wishes or simply to preserve the aesthetic
appearance of building.

Big companies like IKEA or Walmart would be interested in this kind of product because
of low price but professionally manufactured. Theses perks would make it very appealing
to final users. Undoubtedly, furniture manufacturers and DIY stores will be interested in
marketing our goods.

2.3. DESCRIPTION OF DESIGN PROCESS OF SEMINAR WORK INTRODUCE

We developed the project in three phases:
- Functional model. To start with, we began devising an initial model bearing in
mind that only it works in order to achieve the target.

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- Advanced functional model. After the initial model, we created and analyzed
different designs using Solidworks as 3D computer aided design software. This tool
allows us to explore among difference options and possibilities.

- Manufacturing model. Finally we obtained a consensual agreement where different

opinions were taken into consideration. In this way, mechanical properties and
design were improved on the original idea. In particular with respect to the
structural reinforcement as well as the contact point for the table top to support
heavy loads. We all worked together as a team to accomplish the task by using our
knowledge in different subject areas.

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Thanks to the help of Mr. Sherman, our design was printed using a Stratasys printer by
PolyJet 3D printing technology. This technology jets layers of liquid onto a build tray. It
works similarly to inkjet printing which offers surface smoothness, precision and
exceptional detail. Vero Purewhite RGD835 (photopolymer) was used as a raw material.

The following picture shows us the final part. From my point of view, several
improvements can be done. Take for instance; we can get more optimization with regard to
weight and stress. In fact, if we do a finite element analysis (FEA), we will improve the
design and reduce weight. Thus, we will obtain a lower cost.

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 2.4. DISCUSSION OF SELECTED MANUFACTURING METHOD
We chose fused deposition modeling (FDM) as a manufacturing method because pieces
have good mechanical resistance. For this reason, we can use printed part for testing of
prototypes. To print the prototype, we had to decide the best position to the part in order to
reduce support structures and post-processing work. After a short discussion, all the group
members agreed to place the 3D model as follows:

One of the key advantages to using FDM technique is the strong of the finished pieces,
together with the facility to print it for yourself in comparison with others printer
techniques. However, it has its drawbacks too, for example, poorer surface finish and
slower production speed versus others additive manufacturing processes. Another
weakness worth mentioning is the fact that support structures can be required. It would
mean that we should apply post processing tasks to finish the part. Therefore, this involves
spending more time in the production process. Hence, the importance of eliminating or at
least reducing supports.
The main reason why I have chosen this method is because once the prototype had been
improved and tested, the resultant product will be manufactured by using plastic injection
moulding. Make a mould is too expensive, therefore it is quite important to check and try
the prototype before mould construction. This way, it will be considerably reduced
production costs and increase market share. In order to get a competitive product, we need
to be capable of producing very large series and thereby reducing price.

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3. CONCLUSIONS

3.1. CONCLUSIONS OF SEMINAR WORK

Our seminar work included from the initial brainstorming to choose what we wanted to do
to get the ready final product. As far as the work group concerned, we reached the
following conclusions with regard to our final product:
- Product works like it was supposed to do. In fact, we have reached agreement
effectively and according to our knowledge and we have eventually managed to
achieve our target.
- Product has catchy look. We have added to our first idea some customization
topics. This aspect makes it very appealing to potential customers.
- Improving the design is possible. Certainly, the design needs to be analyzed with
FEA software in order to improve weight and mechanical properties.
- The cost of product is too high for commercial potential. As explained above, if the
weight of part is improved, the cost will be improved too.

3.2. CONCLUSIONS OF LITERATURE REVIEW

Generally speaking, it must be said that the course has helped me to grasp the potential of
additive manufacturing. It should be noted that 3d printing is a technology which allows us
to produce complex objects quickly, wherever and with low cost. Nowadays, it is used in
aeronautics, medicine, robotics, art, architecture, dental, fashion and many other industries.
It is not necessary to wait a long time before launching a new product. This perk allows us
to manufacture to customer specifications. Taken everything into account, we can assert
that we are dealing with a powerful technology. All these findings are derived from the
literature review which we have received in the lectures. It is worth mentioning that
moodle platform has been a great support.
In addition, during seminar work we have done a wide range of demos, which helps us to
understand the different technologies used. From my point of view, it provides high added
value to the course and it sparks our interest in additive manufacturing technologies.

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