Additive Manufacturing - Handout

ME2162 / ME2162E / TME2162
Manufacturing Processes
Part I
Woon Keng Soon

mpewks@nus.edu.sg
Chapter 5
Additive Manufacturing / 3D Printing
© Copyright National University of Singapore. All Rights Reserved. ©2019 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 7/e
Additive Manufacturing
Process Flow
STL format
Higher resolution models require more triangles!

Economic Impact
A Brief History (1)
Chuck Hull invented the first AM process called ‘stereolithography’ in 1983.
Stereolithography
A Brief History (3)
SLA-1, the first 3D printer invented by Chuck Hull in 1983.
A Brief History (4)
A Brief History (5)
A Brief History (6)
AM Technologies (2)
AM Technologies (3)
AM Technologies (4)
AM Technologies (5)
Stereolithography & Digital Light Processing (1)
Stereolithography & Digital Light Processing (2)
Both Stereolithography (SLA) and Digital Light Processing (DLP) create 3D

printed objects from a liquid (photopolymer) resin by using a light source to solidify
the liquid material.
To create a 3D printed object, a build platform is submerged into a translucent

tank filled with liquid resin. Once the build platform is submerged, a light located
inside the machine maps each layer of the object through the bottom of the tank,
thus solidifying the material. After the layer has been mapped and solidified by the
light source, the platform lifts up and lets a new layer of resin flow beneath the
object once again. This process is repeated layer by layer until the desired object
has been completed. There are two common methods today differentiated by the
light source: SLA uses a laser, whereas DLP employs a projector.
These 3D printing technologies are also available in desktop 3D printers.

Materials are limited to resins, but new varieties have appeared recently providing
strength or flexibility to the final objects.
SLA & DLP 3D printers produce highly accurate parts with smooth surface
finishes and are commonly used for highly detailed sculptures, jewelry molds, and
prototypes. Because of their relatively small size, they are not recommended for
printing large objects.
Fused Deposition Modeling (1)
The FDM printing process starts with a string of solid material called the
filament. This line of filament is guided from a reel attached to the 3D printer to
a heated nozzle inside of the 3D printer that melts the material. Once in a
melted state, the material can be extruded on a specific and predetermined
path created by the software on the computer. As the material is extruded as a
layer of the object on this path, it instantly cools down and solidifies –
providing the foundation for the next layer of material until the entire object is
manufactured.
As the cheapest 3D printing technology on the market, FDM also offers a wide
variety of plastic-based materials in a rainbow of colors including ABS, PLA,
nylon and even more exotic material blends including carbon, bronze or wood.
FDM is a great choice for quick and low-cost prototyping and can be used for
a wide variety of applications. More recent innovations in FDM 3D printing
include the ability to manufacture functional end products with embedded
electronics and mechanical parts such as drones. Due to some design and
material limitations, FDM 3D printing is not recommended for more intricate
designs.
Selective Laser Sintering (1)
Selective Laser Sintering (SLS) uses a laser to melt and solidify layers of powdered
material into finished objects.
These printers have two beds that are called the pistons. When the printing process
begins, a laser maps the first layer of the object in the powder, which selectively melts –
or sinters – the material. Once a layer has been solidified, the print bed moves down
slightly as the other bed containing the powder moves up; and a roller spreads a new
layer of powder atop the object. This process is repeated, and the laser melts
successive layers one by one until the desired object has been completed.
SLS is mostly used for industrial 3D printing applications. However, the first desktop
versions have already appeared on the market, and the technology is expected to move
further into the mainstream. Materials include various plastics such as polyamides
(nylon), polystyrenes and thermoplastic elastomers.
SLS is widely used for producing functional prototypes and parts as well as some end
products. The biggest advantage of laser sintering is the almost complete design
freedom; excess unmelted powder acts as a support for the structure as it is produced,
which allows for complex and intricate shapes to be manufactured with no additional
support needed. As a side effect of this process, finished objects require more time to
cool and thus, cause longer lead times.
Material Jetting (1)
Material Jetting (Stratasys PolyJet and 3D Systems MultiJet Modeling) technologies
are similar to inkjet printing, but instead of jetting drops of ink onto paper, these 3D
printers jet layers of liquid photopolymer onto a build tray and cure them instantly
using UV light.
The build process begins when the printer jets the liquid material onto the build tray.
These jets are followed by UV light, which instantly cures the tiny droplets of liquid
photopolymer. As the process is repeated, these thin layers accumulate on the build
tray to create a precise object. Where overhangs or complex shapes require support,
the printer jets a removable gel-like support material that is used temporarily, but can
be removed after the print is completed.
Material Jetting is used in industrial 3D printers. Material choices consist of liquid

photopolymers that can provide the final objects various properties including
toughness, transparency or rubber-like flexibility. The most advanced systems can
even use multiple jets that allow for the combination of different material properties
and colors.
Material Jetting offers many advantages for rapid tooling and prototyping, as it allows
users to create realistic and functional prototypes with fine details and precision.
These are the most precise 3D printing technologies today, printing with up to 16-
micron (that's thinner than a human hair) layers.
Binder Jetting (1)
Binder Jetting (2)
The binder jetting technology is similar to SLS in the way that the printer uses
thin layers of powdered material to build up an object, but instead of using a
laser that sinters the layer together, these printers use a binding agent extruded
from a nozzle to bind the powder together.
The process starts with a nozzle spreading the binding agent across the first
layer of the object and binding the powder together. Once the first layer has
been fused with the binding agent, the printing bed moves down slightly and a
thin layer of new powder is spread atop the object. This process repeats until the
desired object has been fully formed. After it is removed from the print bed, the
object is cleaned from excess powder and coated with an adhesive glue to give
it strength and to make it resistant to discoloration.
Binder Jetting is used in industrial 3D printing, with the most common material
being (full-color) sandstone. It is relatively affordable compared to SLS as the
printing process requires less energy, but the printed objects are less strong.
The ability to print in full color has made sandstone popular for architectural
models and lifelike sculptures. Similar to SLS, the benefit of this process is that
the excess unmelted powder acts as a support to the structure as it is being
produced, which allows for complex shapes to be made and no additional
supports are required.
Binder Jetting (3)
Binder Jetting (4)
Binder Jetting (5)
Selective Laser Melting & Electron Beam Melting (1)
Selective Laser Melting and Electron Beam Melting (SLM and EBM) are two of the most
common metal 3D printing technologies. Just like SLS, these processes create objects
from thin layers of powdered material by selectively melting it using a heat source. Due to
the higher melting point of metals they require much more power – a high power laser in
the case of SLM or an electron beam for EBM.
During the printing process, the machine distributes a layer of metal powder onto a build
platform, which is melted by a laser (SLM) or an electron beam (EBM). The build platform
is then lowered, coated with new layer of metal powder on top and the process is repeated
until the object is fully formed. Both SLM and EBM requires support structures, which
anchors the object and overhanging structures to the build platform and enables heat
transfer away from the melted powder. In addition, SLM takes place in a low oxygen
environment and EBM in vacuum, in order to reduce thermal stresses and prevent
warping.
SLM and EBM are used in industrial 3D printing. Materials include various metals and
alloys including steel, titanium, aluminum, cobalt-chrome and nickel.
Metal printing is considered the “holy grail” of additive manufacturing and 3D printing; it is
widely used in the aerospace, aircraft, automotive and healthcare industry for a range of
high-tech, low-volume use cases from prototyping to final production. 3D printed metal
parts allow for monolithic construction (reducing the quantity of components),
miniaturization and mass reduction. SLM and EBM have evolved to a stage where these
prints are comparable to traditionally manufactured parts in terms of chemical composition,
mechanical properties (static and fatigue) as well as microstructure.
Layer Height Effects (1)
Layer Height Effects (2)
Laminated-Object Manufacturing
Characteristics of AM Technologies
Evolution of AM Technologies
Materials for Additive Manufacturing
General Purpose Plastics
High Detail Resin
SLS Nylon
Fiber-Reinforced Nylon
Rigid Opaque Plastic
Rubber-Like Plastic
Transparent Plastic
Simulated Polypropylene
Simulated ABS
Heat Resistant Plastic
Full Colour Sandstone
Industrial Metals
Pros and Cons (1)
Pros and Cons (2)
Pros and Cons (3)
Pros and Cons (4)
Pros and Cons (5)
End Users
End Users: Car Manufacturers
End Users: Doctors
End Users: Dentists
End Users: Prosthetics
End Users: Aircraft Manufacturers
End Users: Aerospace Companies
End Users: Prop Makers
End Users: Product Designers
End Users: Architects
End Users: Students
End Users: Design Entrepreneurs
End Users: Engineers
End Users: Drone Enthusiasts
End Users: Shoe Manufacturers
End Users: Consumer Product Makers
Targeted End Markets
Pros and Cons (1)
Pros and Cons (2)
Pros and Cons (3)
Hype Cycle
Stage 2
Stage 5
Stage 4
Stage 3
Stage 1
Hype Cycle on 3D Printing - 2011
4D Printing
A single print, with multi-material features, can

transform from any 1D strand into 3D shape, 2D surface
into 3D shape or morph from one 3D shape into another.
Hype Cycle 2017
Hype Cycle 2018
Hype Cycle 2019
Nanoscale 3D Printing
Nanoscale 3D printing uses two-photon lithography

(TPL) techniques to produce ultra fine features smaller
than a fraction of the width of a human hair.
Digitalization
Humanitarian Work
Field Ready 3D-printing a water pipeline joint
replacement at the point of need, Nepal
Water tap prototypes
Automotive
Medical Technology
Food
Printed food in chocolate and mashed potatoes
Foodini Food Printer

Three stages of a printed pizza
Summary
• Different classes of 3D printing technologies
• Major characteristics comparisons
• General materials for 3D printing technologies
• Analysis of major end-user groups and applications
• Analysis of current trends and oppurtunities

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ME2162 / ME2162E / TME2162

Woon Keng Soon

Additive Manufacturing / 3D Printing

Higher resolution models require more triangles!

Chuck Hull invented the first AM process called ‘stereolithography’ in 1983.

SLA-1, the first 3D printer invented by Chuck Hull in 1983.

Both Stereolithography (SLA) and Digital Light Processing (DLP) create 3D

To create a 3D printed object, a build platform is submerged into a translucent

These 3D printing technologies are also available in desktop 3D printers.

Material Jetting is used in industrial 3D printers. Material choices consist of liquid

A single print, with multi-material features, can

Nanoscale 3D printing uses two-photon lithography

Foodini Food Printer

• Different classes of 3D printing technologies

• Major characteristics comparisons

• General materials for 3D printing technologies

• Analysis of major end-user groups and applications

• Analysis of current trends and oppurtunities

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