3D Printing: Chapter 1

ya got it bro

Motivations of Additive Manufacturing

• need products to reach market ASAP

• 3D printing has an impact on the product development process through prototyping

Types of Prototypes

1. Implementation of the prototype

2. Form of the prototype

3. Degree of the approximation (representativeness) of the prototype

Types of implementation

1. Complete: finished prototypes that can preform their function

2. Component: still needed to be assembeled

Types of Form

1. Virtual

2. Physical

Virtual prototyping and its benefits

• non-tangible, cheaper, used when a prototype is too large, can be easily changed, for visualization!

• benefits (recap)

  • speed

  • cost effecitve

  • visualization

  • collaboration

  • integration with simulations

Physical prototyping and its benefits

• tangible, used for testing, experimentation, and human factors

• benefits:

  • tactile

  • functional

  • can validate material

  • stakeholders and investors engagement

Degree of Approximation Types

1. Rough: used to test and study problems

2. Accurate: is an exact full scale replica. Used in the end stage

Basic Approach of AM systems

1. a model is made on CAD and represented as closed surfaces

2. converted into a STL file

3. splits the model into cross sections

Fundamentals of AM (additive manufacturing)

• input

• method

• material

• application

Input

• the electronic info needed to describe an object in 3D

• done through a computer model or a physical model

Types of Methods

1. photo-curing & laser

2. cutting and joining

3. melting and solidifying/fusing

4. joining/binding

Initial State of Materials

1. Solid

2. Liquid

3. Powder

Applications can be grouped into…

1. Design

2. Engineering Analysis and Planning

3. Tooling and Manufacturing

Advantages of Additive Manufacturing

• Automated

• Can produce small quantities and quality

• can be close to the final product

• less time needed

Product Designer Benefits

• fewer constraints

• less use of material

• less use of time

• parts that are difficult for machining, can be designed

Tooling & Manufacturing Engineer Benefits

• lower costs

• reduced labor

• reduced material waste

• reduced inventory

Indirect Benefits to Marketing

reduce time-to-market so…

• less risk

• able to fit customer needs

• offer latest technology

Indirect Benefits to Supply Chain

• increase diversity of products

• expand distribution

Indirect Benefits to Consumer

• wider diversity of products

• can buy (and design) products

• products are more affordable

Agility in manufacturing

• no constraints

• digital files can be changed at any time

Processing Technology

Binder Jetting, Powder Bed Fusion, Direct Energy Deposition, Material Jetting, Material Extrusion, Sheet Lamination, Vat Photo-polymerization

Binder jetting

• when a liquid bonding agent is selectively deposited to join powder materials

Powder bed fusion

• When thermal energy selectively fuses regions of a powder bed

Direct energy deposition

• where focused thermal energy is used to fuse materials by melting as they are being deposited

Material extrusion

• when a material is selectively dispensed through a nozzle or orifice

Material jetting

Where droplets of build material are selectively deposited

Sheet lamination

• where sheets of material are bonded to form an object

Vat photopolymerisation

• where liquid photopolymer in a vat is selectively cured by light-avtivated polymerization