Additive Manufacturing (Friday lectures 1,2)

Page 2: Lectures Outline

Introduction

• Overview of the processes in Additive Manufacturing (AM) including

  • The 7 AM methods

  • Extrusion (FDM)

  • Photopolymerisation (SLA)

Page 3: Learning Objectives

Aim

• Provide an overview of the importance of additive manufacturing.

• Appreciate the design considerations for AM and the associated opportunities and limitations.

Specific Objectives

• Gain knowledge of the working principles of the 7 classes of AM technology.

• Evaluate the use of AM across different manufacturing industries.

• Identify the AM process workflow for specific applications and classes of AM.

• Assess current trends in AM.

Page 4 & 5: Additive Manufacturing Definition

Definition

• Additive Manufacturing (AM) is a process that utilizes digital 3D design data to construct components in layers by depositing materials.

• Synonym: 3D printing is often used interchangeably with AM.

Page 6: The Generic AM Process

Process Steps

1. CAD: Begin with a Computer-Aided Design model.

2. File Conversion: Convert the CAD file to *.stl format.

3. File Transfer: Transfer the file to the AM machine.

4. Machine Setup: Configure the machine settings.

5. Build: Execute the build process.

6. Remove: Carefully remove the finished part from the machine.

7. Post-process: Conduct any necessary post-processing.

8. Application: Use the finished product in its intended application.

The early stages of designing may only require rough parts

HISTORY _ NOT RELEVENT?

Page 7: A Brief History of 3D Printing

Early Developments (1980s - 1990s)

• Dr. Kodama: Pioneered a layer-by-layer manufacturing approach.

• Stereolithography: Developed by a French research group.

• First Patent: Charles Hull secured the first patent for stereolithography.

• Market Introduction:

  • First SLA-1 machine

  • First SLS machine: DTM launches SinterStation 2000

Page 8: Continual Advancements in 3D Printing

Market Growth (1980s - 1990s)

• Introduction of new systems:

  • EOS launched additional SLA systems.

  • Quadrax introduced the Mark 1000.

  • Zcorp launched the Z402 printer.

• FDM Market Entry: Stratasys released The 3D Modeller.

• Laminated manufacturing became viable with Helisys (LOM 1015).

• Advancements in metal printing: EOS launched EOSINT M250.

Page 9: Major Innovations (2000s - 2010s)

Milestones

• First Multijet Modeller released by Objet Geometries: Quadra 3D printer.

• 3D printing of functional tissue: A working kidney is 3D printed.

• The emergence of RepRap, an open-source self-replicating 3D printer.

• Successful printing of functional organs and blood vessels from stem cells.

• Landmark projects:

  • KOR Ecologic produced the first 3D printed car.

  • Southampton University created a 3D printed aircraft.

  • LayerWise developed a 3D printed jaw implant.

  • 3D Systems innovated a hybrid exoskeleton robotic suit.

Page 10: The AM Industry Today

Industry Overview

• Insights from the 3D Printing Hype Cycle by Gartner.

  

See the five stages across the bottom The dip in the middle is due to failing or not working as expected and people believe that it won’t live up to potential.

High innovation potential in the future of the field

Page 11: AM Industry Stats

Market Insights

• Wohlers Report 2018: AM industry exceeds $7.3 billion.

• Total worldwide manufacturing value stands at $15 trillion, with AM representing only 0.02% of this economy.

• Rapidly growing industry

• 

Page 12: Current Use Cases

Applications of 3D Printing

• Key use cases in AM:

  • Tooling

  • Components for various applications

  • Patterns for prototype presentations

  • Functional parts production

  • Patterns for metal casting

  • Educational and research purposes

    

Page 13: Future Projections

Market Size Estimates (2014-2027)

• Total market size for AM by opportunity segments:

  • Looks into future expectations as detailed in the SmarTech Publishing report 2018.

    

Key additive manufacturing industries include aerospace, healthcare, automotive and service as well ad consumer goods, energy and industrial

Page 14: Factors Behind AM Growth

Significant Contributors

• Drivers for AM Popularity:

  • Accessible CAD/CAM software availability.

  • Improved automation and component technologies.

  • An expanding library of printable materials.

  • Increased investment from industries and governments.

  • Patent expirations providing operational freedom.

  • Fast prototyping capabilities.

  • Ability to create complex geometries.

  • Use of multiple and novel materials.

  • Enhanced performance benefits.

  • Low-volume manufacturing possibilities (personalization).

  • Growing momentum, confidence, and creativity in the field.

Page 15: Cost Comparisons

Manufacturing Costs

• Analyzes cost implications between conventional production and AM innovations.

  

The industry has boomed since there is no need for expensive tooling like there is for injection moulding (for example). So in this case (injection molding) you would need to make and sell hundreds of thousands of parts otherwise production cost would be too high In conventional manufacturing, increasing complexity and customisarion leads to increased cost, whereas additive manufacturing allows for greater design freedom without significantly raising costs, making it more feasible for low-volume production runs with little effort.

Page 16: Complexity Considerations

Production Complexity

• Highlights the differences in production complexity between conventional methods and AM, with emphasis on geometrical and design advantages.

Page 17: Geometry and Production

Machinability Considerations

• Discusses machinable geometry parameters when comparing traditional methods with AM capabilities, assessing the advantages of AM in certain production scenarios.

Page 18: Benefits of AM

Manufacturing Advantages

• Tool-less manufacturing technology allows for:

  • Design flexibility without constraints.

  • Product customization capabilities.

  • Direct assembly off the AM system.

  • Development of new business models and enhanced supply chains.

  • Potential for sustainable manufacturing practices.

Page 19: Industrial Applications

Notable Uses of AM

• Examples of Diverse Industrial Uses:

  • 3D-printed fuel nozzle enhancing engine efficiency by 15%.

  • “Bionic” wing bracket designed for Airbus A350 XWB jet.

  • Unique 3D-printed shoes.

  • 3D printed components shown in the Skyfall film.

  • Custom airway stent for medical applications.