Additive Manufacturing: Chapter 1 PDF

Chapter 1 Introduction and Basic Principles  Introduction and Basic Principles Objectives: – Discuss on: What is additive manufacturing? What are AM parts used for? The generic AM process – CAD; Conversion to STL; Transfer to AM machine and STL file and STL...

Chapter 1 Introduction and Basic Principles  Introduction and Basic Principles Objectives: – Discuss on: What is additive manufacturing? What are AM parts used for? The generic AM process – CAD; Conversion to STL; Transfer to AM machine and STL file and STL manipulation; Machine setup; Build; Removal; Post-processing; and Application Why use the term additive manufacturing? – Automated fabrication (autofab); Freeform fabrication or solid freeform fabrication; Additive manufacturing or layer based manufacturing; Stereolithography or 3Dprinting; and Rapid prototyping The benefits of AM Distinction between AM and CNC machining – Material; Speed; Complexity; Accuracy; Geometry; and Programming Introduction and Basic Principles Example AM parts Other related technologies – Reverse engineering technology; Computer-aided engineering; and Haptic-based CAD Assignment: – Read Chapter 1, Pages 1 - 18 Homework: – Exercises: 1-7 YouTube Videos Hyperboloid Print http://www.youtube.com/watch?v=1213kMys6e8 Hyperboloid Timelapse https://www.youtube.com/watch?v=NzQF7SRU_1E 3D Printed Jet Engine Assembly Guide - Condensed Version https://www.youtube.com/watch?v=AfvY2CTTjUE What is Additive Manufacturing? Additive Manufacturing (AM) refers to a process by which digital 3D design data is used to build up a component in layers by depositing material (From the International committee F42 for Additive Manufacturing technologies, ASTM). The term “3D printing” is increasingly used as a synonym for AM. However, the latter is more accurate in that it describes a professional production technique which is clearly distinguished from conventional methods of material removal. Instead of milling a workpiece from solid block, for example, AM builds up components layer by layer using materials which are available in fine powder form. A range of different metals, plastics, and composite materials may be used. Additive Manufacturing Additive manufacturing (AM): process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. Synonyms: additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing, and freeform fabrication. What is Rapid Prototyping?  STL File Format (3.00, -1.00, 1.00) z y x  Why does AM have value? Reduces engineering changes – Cost of engineering changes increase by an order of magnitude as the design moves into the next stage of development: $1,000,000.0 $100,000.00 $10,000.00 $1,000.00 $100.00 $10.00 $1.00 Conceptual Detail Design Prototype Tooling Production Field Service Design  Why does AM have value? Reduces engineering changes – Cost of engineering changes increase by an order of magnitude as the design moves into the next stage of development: $1,000,000.0 $100,000.00 $10,000.00 $1,000.00 $100.00 $10.00 $1.00 Conceptual Detail Design Prototype Tooling Production Field Service Design  Rapid Prototyping Technologies Concept Modelers 3D Systems ProJetTM Objet Eden500V Stratasys Dimension Z Corp ZPrinter® envisionTEC Solidscape 650 Perfactory® T66  Rapid Prototyping Technologies Main Frame Machines 3D Systems iProTM 3D Sys. Stratasys 9000 Sinterstation®Pro 900mc eos EOSINT Arcam Arcam fcubic P730 A2 StereoLithography Apparatus (SLA®-5000) StereoLithography Apparatus (SLA®-3500 and 250s) Selective Laser Sintering (SLS®-2500plus) Fused Deposition Modeling (FDM Titan)  ® Spectrum Z510 System  TM REVscan Laser Scanner Phantom – Digital Clay  Exercises 1. Find three other definitions for Rapid Prototyping other than that covered by this book. 2. From the web, find different examples of applications of AM that illustrate their use for “Form”, “Fit”, and “Function”. 3. What functions can be carried out on point cloud data using Reverse Engineering software? How do these tools differ from conventional 3D CAD software 4. What is your favorite term (AM, Freeform Fabrication, RP, etc.) for describing this technology and why? 5. Create a web link list of videos showing operation of different AM technologies and representative process chains. 6. Make a list of different characteristics of AM technologies as a means to compare with CNC machining. Under what circumstances do AM have the advantage and under what would CNC? 7. How does the Phantom desktop haptic device work and why is it more useful for creating freeform models than conventional 3D CAD?