AM UNIT 2-1

Department of civil Engineering , ADITYA COLLEGE OF ENGINEERING & TECHNOLOGY
ADDITIVE MANUFACTURING
Handling by
Mr. P.Uma maheswara rao. M.Tech.,
Assistant Professor
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UNIT– II: SOLID-BASED RAPID PROTOTYPING SYSTEMS: Laminated

object manufacturing (LOM) - models and specifications, process, working principle,
applications, advantages and disadvantages, case studies. Fused deposition modelling
(FDM) - models and specifications, process, working principle, applications,
advantages and disadvantages, case studies.
Laminated object manufacturing(LOM) Fused deposition modelling (FDM)

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Laminated object manufacturing (LOM)

Laminated object manufacturing (LOM) is a rapid prototyping process. It is generally
considered a type of 3D printing. LOM creates models by layering sheets of build material. The
sheets are bonded through heat and pressure and shaped using either a blade or a laser. This
makes LOM both an additive (like 3D printing) and subtractive process.
An LOM machine uses a continuous sheet of material. The sheet is fed onto the building
platform using heated rollers. Adhesive is applied through a nozzle. After a layer has been
rolled onto the platform, a computer-controlled laser or blade carves a 2D pattern into it. The
process is repeated layer by layer.
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4.1.3 Process The patented Laminated Object Manufacturing® (LOMTM) process [2–4] is an
automated fabrication method in which a 3D object is constructed from a solid CAD
representation by sequentially laminating the part cross-sections.
The process consists of three phases:

1.pre-processing;
2.building;
3.post-processing
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4.1.5 Advantages and Disadvantages The main advantages of using LOMTM technology are
as follows:
(1) Wide variety of materials. In principle, any material in sheet form can be used in the LOMTM
systems. These include a wide variety of organic and inorganic materials such as paper,
plastics, metals, composites and ceramics. Commercial availability of these materials allow
users to vary the type and thickness of manufacturing materials to meet their functional
requirements and specific applications of the prototype.
(2) (2) Fast build time. The laser in the LOMTM process does not scan the entire surface area of
each cross-section, rather it only outlines its periphery. Therefore, parts with thick sections are
produced just as quickly as those with thin sections, making the LOMTM process especially
advantageous for the production of large and bulky parts.
(3) High precision. The feature to feature accuracy that can be achieved with LOMTM machines
is usually better than 0.127 mm (0.005"). Through design and selection of application specific
parameters, higher accuracy levels in the X–Y and Z dimensions can be achieved. If the layer
does shrink horizontally during lamination, there is no actual distortion as the contours are cut
post-lamination, and laser cutting itself does not cause shrinkage. If the layers shrink in the
transverse direction, a closed-loop feedback system gives the true cumulative part height upon
each lamination to the software, which then slices the 3D model with a horizontal plane at the
appropriate location. 13
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Disadvantages
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4.1.7 Example
4.1.7.1 National Aeronautical and Space Administration (NASA) and Boeing
Rocketdyne Uses LOMTM to Create Hot Gas Manifold for Space Shuttle Main
Engine [8] One successful example of how an organization implements LOMTM
systems into their design process would be from the Rapid Prototyping Laboratory,
NASA’s Marshall Space Flight Center (MSFC), Huntville, AL. The laboratory was set
up initially to conduct research and development in different ways to advance the
technology of building parts in space by remote processing methods. However, as
MSFC engineers found a lot more useful applications, i.e., production of concept
models and proof-out of component designs other than remote processing when rapid
prototyping machines were installed, the center soon became a rapid prototyping shop
for other MSFC groups, as well as other NASA locations and NASA subcontractors.
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Fused deposition modelling (FDM):

Fused deposition modeling (FDM) 3D printing, also known as fused filament fabrication
(FFF), is an additive manufacturing (AM) process within the realm of material extrusion.
FDM builds parts layer by layer by selectively depositing melted material in a
predetermined path. It uses thermoplastic polymers that come in filaments to form the final
physical objects.
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In this patented process [12], a geometric model of a conceptual design is created on a

CAD software which uses IGES or STL formatted files.
It can then imported into the workstation where it is processed through the QuickSlice®
and SupportWorkTM propriety software before loading to FDM 3000 or similar
systems.
For FDM Maxum and Titan, a newer software known as Insight is used. The basic
function of Insight is similar to that of QuickSlice® and the only difference is that
Insight does not need another software to auto-generate the supports.
The function is incorporated into the software itself. Within this software, the CAD file
is sliced into horizontal layers after the part is oriented for the optimum build position,
and any necessary support structures are automatically detected and generated.
The slice thickness can be set manually to anywhere between 0.172 to 0.356 mm (0.005
to 0.014 in) depending on the needs of the models. Tool paths of the build process are
then generated which are downloaded to the FDM machine. 20
The modeling material is in spools — very much like a fishing line. The filament on the spools is
fed into an extrusion head and heated to a semi-liquid state.
The semi-liquid material is extruded through the head and then deposited in ultra thin layers from
the FDM head, one layer at a time.
Since the air surrounding the head is maintained at a temperature below the materials’ melting
point, the exiting material quickly solidifies.
Moving on the X–Y plane, the head follows the tool path generated by QuickSlice® or Insight
generating the desired layer.
When the layer is completed, the head moves on to create the next layer. The horizontal width of
the extruded material can vary between 0.250 to 0.965 mm depending on model.
This feature, called “road width”, can vary from slice to slice. Two modeler materials are
dispensed through a dual tip mechanism in the FDM machine.
A primary modeler material is used to produce the model geometry and a secondary material, or
release material, is used to produce the support structures. The release material forms a bond
with the primary modeler material and can be washed away upon completion of the 3D models.
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4.2.5 Advantages and Disadvantages The main advantages of using FDM

technology are as follows:
(1) Fabrication of functional parts. FDM process is able to fabricate prototypes with materials
that are similar to that of the actual molded product. With ABS, it is able to fabricate fully
functional parts that have 85% of the strength of the actual molded part. This is especially
useful in developing products that require quick prototypes for functional testing.
(2) Minimal wastage. The FDM process build parts directly by extruding semi-liquid melt onto
the model. Thus only those material needed to build the part and its support are needed, and
material wastages are kept to a minimum. There is also little need for cleaning up the model
after it has been built.
(3) Ease of support removal. With the use of Break Away Support System (BASS) and Water
Works Soluble Support System, support structures generated during the FDM building process
can be easily broken off or simply washed away. This makes it very convenient for users to get
to their prototypes very quickly and there is very little or no post-processing necessary.
(4) Ease of material change. Build materials, supplied in spool form (or cartridge form in the
case of the Dimension or Prodigy Plus), are easy to handle and can be changed readily when
the materialsin the system are running low. This keeps the operation of the machine simple and
the maintenance relatively easy. 24
Disadvantages of using FDM technology are as follows:

(1) Restricted accuracy. Parts built with the FDM process usually have restricted accuracy due
to the shape of the material used, i.e., the filament form. Typically, the filament used has a
diameter of 1.27 mm and this tends to set a limit on how accurately the part can be built.
(2) Slow process. The building process is slow, as the whole crosssectional area needs to be
filled with building materials. Building speed is restricted by the extrusion rate or the flow rate
of the build material from the extrusion head. As the build material used are plastics and their
viscosities are relatively high, the build process cannot be easily speeded up.
(3) Unpredictable shrinkage. As the FDM process extrudes the build material from its extrusion
head and cools them rapidly on deposition, stresses induced by such rapid cooling invariably
are introduced into the model. As such, shrinkages and distortions caused to the model built are
a common occurrence and are usually difficult to predict, though with experience, users may be
able to compensate for these by adjusting the process parameters of the machine.
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Department of civil Engineering , ADITYA COLLEGE OF ENGINEERING & TECHNOLOGY

UNIT– II: SOLID-BASED RAPID PROTOTYPING SYSTEMS: Laminated

Laminated object manufacturing(LOM) Fused deposition modelling (FDM)

Laminated object manufacturing (LOM)

The process consists of three phases:

Fused deposition modelling (FDM):

In this patented process [12], a geometric model of a conceptual design is created on a

4.2.5 Advantages and Disadvantages The main advantages of using FDM

Disadvantages of using FDM technology are as follows:

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