Additive Manufacturing (ME 134) PDF

Additive Manufacturing University of the Philippines Diliman – Department of Mechanical Engineering Additive Manufacturing (AM) Refers to a class of technologies that can automatically construct physical models from Computer-Aided Design (CAD) data. In this method, physical models...

Additive Manufacturing University of the Philippines Diliman – Department of Mechanical Engineering Additive Manufacturing (AM) Refers to a class of technologies that can automatically construct physical models from Computer-Aided Design (CAD) data. In this method, physical models are formed by adding materials layer by layer. The first techniques for rapid prototyping became available in the late 1980s. Synonymous to 3D printing University of the Philippines Diliman – Department of Mechanical Engineering  Why is AM relevant? SALES Others Metal tooling 3% 4% Functional Polymer pattern proptotypes 7% 25% Jigs and fixtures 7% Cosmetic models 10% End use parts Education research 32% 12% The applications of additive manufacturing (Wohlers Report 2021) University of the Philippines Diliman – Department of Mechanical Engineering Machining vs AM University of the Philippines Diliman – Department of Mechanical Engineering Machining vs AM University of the Philippines Diliman – Department of Mechanical Engineering Applications Art Dental applications Automotive industry Bioengineering Aerospace applications Fashion University of the Philippines Diliman – Department of Mechanical Engineering Additive Manufacturing Process 1.Geometric Modelling 2.Tessellation of the geometric model 3.Slicing of the model into thin cross-sectional layers 4.Constructing the model 5.Finishing and cleaning University of the Philippines Diliman – Department of Mechanical Engineering 1. Geometric Modeling Pro/Engineer Fusion360 SolidWorks University of the Philippines Diliman – Department of Mechanical Engineering 2. Tessellation University of the Philippines Diliman – Department of Mechanical Engineering 3. Slicing University of the Philippines Diliman – Department of Mechanical Engineering 4. Constructing of Layers ⚬ RP machines build one layer at a time University of the Philippines Diliman – Department of Mechanical Engineering  5. Cleaning and Finishing https://freerkset.live/product_details/44941118.html https://www.granbo.com/3d-printing-ultrasonic-cleaner University of the Philippines Diliman – Department of Mechanical Engineering 5. Cleaning and Finishing University of the Philippines Diliman – Department of Mechanical Engineering 5. Cleaning and Finishing University of the Philippines Diliman – Department of Mechanical Engineering Additive Manufacturing Technologies University of the Philippines Diliman – Department of Mechanical Engineering  Fused Deposition Modelling (FDM) Thermoplastics, Metal powders Stereolithography (SLA) Photopolymers Selective Laser Sintering (SLS) Thermoplastics, Metal Powders Laminated Object Manufacturing (LOM) Paper Electron Beam Melting (EBM) Titanium Alloys AM Technologies Base Materials University of the Philippines Diliman – Department of Mechanical Engineering Fusion Deposition Modeling (FDM) University of the Philippines Diliman – Department of Mechanical Engineering Fused Deposition Modeling (FDM) (FDM) is a solid-based rapid prototyping method that extrudes material, layer-by-layer, to build a model. Support material is required https://www.researchgate.net/figu re/Fused-deposition-modeling- technology_fig1_282584691 University of the Philippines Diliman – Department of Mechanical Engineering FDM Process Filament is melted in a nozzle that moves in XY direction Molten plastic is then extruded from the nozzle and then Deposited on the build platform in layers until the part is finished University of the Philippines Diliman – Department of Mechanical Engineering Fused Deposition Modeling (FDM) University of the Philippines Diliman – Department of Mechanical Engineering Stereolithography (SLA) University of the Philippines Diliman – Department of Mechanical Engineering  FDM Process Laser traces the path of the geometry/pattern that is being produced. The resin hardens after laser exposure. Build platform descends, and the process repeats. https://www.custompartnet.com/wu/stereolithography University of the Philippines Diliman – Department of Mechanical Engineering Stereolithography (SLA) University of the Philippines Diliman – Department of Mechanical Engineering Selective Laser Sintering (SLS) University of the Philippines Diliman – Department of Mechanical Engineering FDM Process Layer of powder is placed in fabrication bed. High power laser fuses the powder that it traced. The fabrication bed is then lowered and anew layer of powder is spread. University of the Philippines Diliman – Department of Mechanical Engineering SLS polyamide (nylon) material enables full functional The surface finish of SLS parts are not good as SLA parts prototype production. but additional surface finish can be applied. Glass-filled nylon is resistant to high temperature and High shrinkage ratios can result torsion, bending or chemical environments in the prototype production. dimensional inaccuracy. Rubber like parts can be manufactured directly from polymer. This is for seals and sealing elements that are SLS feature details are not precise as in SLA. exposed to high temperature. Advantages Disadvantages University of the Philippines Diliman – Department of Mechanical Engineering Selective Laser Sintering (SLS) University of the Philippines Diliman – Department of Mechanical Engineering Laminated Object Manufacturing (LOM) University of the Philippines Diliman – Department of Mechanical Engineering Laminated Object Manufacturing (LOM) University of the Philippines Diliman – Department of Mechanical Engineering  The most common used material is still paper. The materials Low cost due to readily available raw material on any other specified is currently underway. As parts are easily to accommodate to humidity finishing Relatively large parts may be made, because no chemical should be applied with a special Epoxy based material reaction is necessary (Lompoxy: generated for LOM usage). Fast as laser only traces the contour and does not trace the Production of complex parts are difficult. whole cross section. Parts can be used immediately after processing. There is no There may be fire problem when the working zone gets too need for Additional processing. hot. No need for additional support. Very easy to use Advantages Disadvantages University of the Philippines Diliman – Department of Mechanical Engineering Laminated Object Manufacturing (LOM) University of the Philippines Diliman – Department of Mechanical Engineering Electron Beam Melting (EBM) University of the Philippines Diliman – Department of Mechanical Engineering Electron Beam Melting (EBM) It is process wherein parts are formed by melting metal powder layer per layer with an electron beam in a high vacuum. Titanium alloys are widely used in this technology which makes it suitable choice for medical implant market. University of the Philippines Diliman – Department of Mechanical Engineering  EBM CHARACTERISTICS no need for high surface extra heat quality treatment Applicable to Minimum layer metals, ceramics thickness at and composites 0.05mm Used in medical Precise implants, aerospace process and automotive parts High quality vacuum melting enables high Vacuum requirement entails additional material properties costs. Oxide and nitride-based impurities are Emits gamma rays during operation avoided Compared to SLS, EBM has higher power Materials should be electrically conductive and speed Advantages Disadvantages University of the Philippines Diliman – Department of Mechanical Engineering Electron Beam Melting (EBM) University of the Philippines Diliman – Department of Mechanical Engineering