Lecture Slides

Introduction to Additive Manufacturing

Lecture Overview

• Course: Introduction to Additive Manufacturing (MECH3775)

• Instructor: Robert Kay

• Email: R.W.Kay@leeds.ac.uk

Learning Objectives

• Define Additive Manufacturing (AM)

• Explore current trends and implications of AM

• Understand terminology associated with AM

• Review AM process categories per ASTM F42 standards

• Recognize the 5 stages from CAD to part in AM:

  • CAD – designing the product model

  • STL – converting to STL file

  • Setup Build – preparing the 3D printer

  • Manufacture Component – 3D printing process

  • Post Process – finishing components (e.g., support removal)

• Identify common uses for AM

• Assess advantages and disadvantages of AM

• Discuss current limitations of AM

The Evolution and Impact of 3D Printing

Media Perspectives

• The Economist highlighted the shift towards digital manufacturing, suggesting a potential third industrial revolution.

• Coverage from BBC News indicated concerns over the implications of 3D printing, such as the production of weapons and drugs.

• The rise of 3D printing has spurred various applications in medicine, art, and even the food industry. Draws attention to innovations like printed organs and prosthetics.

Government Regulations and Initiatives

• Custom Ministers express concerns regarding regulation and control of 3D printed items.

• Major investment and initiatives in AM are taking place globally (e.g., USA’s National AM Innovation Institute).

AM Process Categories

ISO/ASTM 52900 Standard Categories

1. Material Extrusion: Material forced through a nozzle (e.g., FDM)

2. Vat Photopolymerization: UV light cures liquid resin in a vat (e.g., SLA)

3. Powder Bed Fusion: Selective fusing of powder using thermal energy (e.g., SLS)

4. Material Jetting: Droplets of build material deposited layer by layer

5. Binder Jetting: Liquid bonding agent joining powder materials

6. Directed Energy Deposition: Material melts as it is being deposited, used for repairing or adding to existing structures

7. Sheet Lamination: Sheets of material bonded to form an object

Applications of Additive Manufacturing

Common Uses

• Product Development: Rapid prototyping of new designs

• Customization: Tailored products for individual needs

• Reverse Engineering: Creating models based on existing items

• Rapid Tooling: Quick manufacturing of production tools

Notable Examples of AM in Action

• 3D printed homes built quickly with innovative technology

• Custom medical implants and prosthetics (e.g., hearing aids, dental aligners).

• Food Printing: Initial projects have printed various food items, showcasing versatility in material use.

Challenges and Limitations of AM

Current Limitations

• Limited material selection and properties

• Variability in resolution and surface finish

• Low throughput compared to traditional manufacturing methods

• Concerns regarding post-processing needs (e.g., support structure removal)

• High costs associated with materials and maintenance of 3D printing equipment

The Future of Additive Manufacturing

Trends

• Continuous advancements in AM technology promise to make processes cheaper and more accessible

• Growing interest from industries in utilizing low-volume production facilitated by AM

• Increasing presence of home user 3D printers indicates a potential for significant shifts in consumer behavior regarding product availability and customization

Outlook

• Ongoing research and development will enhance material capabilities, process efficiencies, and the overall impact of AM across various sectors.