An Autonomous Institution

Affiliated to VTU, Belagavi,

Approved by AICTE, New Delhi,
Recognised by UGC with 2(f) & 12 ( B)
Accredited by NBA & NAAC

MVJ22ME643
Additive Manufacturing
Department of Mechanical Engineering

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 Module 1
Introduction to Additive Manufacturing: Introduction to AM, AM evolution, Distinction between
AM & CNC machining, Advantages of AM, AM process chain: Conceptualization, CAD,
conversion to STL, Transfer to AM, STL file manipulation, Machine setup, build , removal and
clean up, post processing.
Classification of AM processes: Liquid polymer system, Discrete particle system, Molten
material systems and Solid sheet system.
Post processing of AM parts: Support material removal, surface texture improvement, accuracy
improvement, aesthetic improvement, preparation for use as a pattern, property enhancements
using non-thermal and thermal techniques.
Guidelines for process selection: Introduction, selection methods for a part, challenges of
selection
AM Applications: Functional models, Pattern for investment and vacuum casting, Medical
models, art models, Engineering analysis models, Rapid tooling, new materials development, Bi-
metallic parts, Re-manufacturing. Application examples for Aerospace, defence, automobile, Bio-
medical and general engineering industries

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 Module 2

System Drives and devices: Hydraulic and pneumatic

motors and their features, Electrical motors AC/DC and
their features
Actuators: Electrical Actuators; Solenoids, Relays,
Diodes, Thyristors, Triacs, Hydraulic
and Pneumatic actuators, Design of Hydraulic and
Pneumatic circuits, Piezoelectric actuators, Shape
memory alloys.

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 Module 3
POLYMERS & POWDER METALLURGY Basic Concepts: Introduction to Polymers used for additive
manufacturing: polyamide, PF resin, polyesters etc. Classification of polymers, Concept of functionality,
Polydispersity and Molecular weight [MW], Molecular Weight Distribution [MWD] Polymer Processing:
Methods of spinning for additive manufacturing: Wet spinning, Dry spinning. Biopolymers, Compatibility issues
with polymers. Moulding and casting of polymers, Polymer processing techniques General Concepts:
Introduction and History of Powder Metallurgy (PM), Present and Future Trends of PM Powder Production
Techniques: Different Mechanical and Chemical methods, Atomisation of Powder, other emerging processes.
Characterization Techniques: Particle Size & Shape Distribution, Electron Microscopy of Powder, Interparticle
Friction, Compression ability, Powder Structure, Chemical Characterization Microstructure Control in Powder:
Importance of Microstructure Study, Microstructures of Powder by Different techniques. Powder Shaping:
Particle Packing Modifications, Lubricants & Binders, Powder Compaction & Process Variables, Pressure &
Density Distribution during Compaction, Isotactic Pressing, Injection Moulding, Powder Extrusion, Slip Casting,
Tape Casting. Sintering: Theory of Sintering, Sintering of Single & Mixed Phase Powder, Liquid Phase
Sintering Modern Sintering Techniques, Physical & Mechanical Properties Evaluation, Structure-Property
Correlation Study, Modern Sintering techniques, Defects Analysis of Sintered Components Application of
Powder Metallurgy: Filters, Tungsten Filaments, Self-Lubricating Bearings, Porous Materials, Biomaterials etc.

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 Module 4
NANO MATERIALS & CHARACTERIZATION TECHNIQUES: Introduction: Importance of Nano-
technology, Emergence of Nanotechnology, Bottom-up and Top-down approaches, challenges in
Nanotechnology Nano-materials Synthesis and Processing: Methods for creating Nanostructures;
Processes for producing ultrafine powders- Mechanical grinding; Wet Chemical Synthesis of Nano-
materials- sol-gel process; Gas Phase synthesis of Nano-materials- Furnace, Flame assisted
ultrasonic spray pyrolysis; Gas Condensation Processing (GPC), Chemical Vapour
Condensation(CVC). Optical Microscopy - principles, Imaging Modes, Applications, Limitations.
Scanning Electron Microscopy (SEM) - principles, Imaging Modes, Applications, Limitations.
Transmission Electron Microscopy (TEM) - principles, Imaging Modes, Applications, Limitations. X-
Ray Diffraction (XRD) - principles, Imaging Modes, Applications, Limitations. Scanning Probe
Microscopy (SPM) - principles, Imaging Modes, Applications, Limitations. Atomic Force Microscopy
(AFM) - basic principles, instrumentation, operational modes, Applications, Limitations. Electron
Probe Micro Analyzer (EPMA) - Introduction, Sample preparation, Working procedure, Applications,
Limitations.

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 Module 5

MANUFACTURING CONTROL AND AUTOMATION CNC technology - An

overview: Introduction to NC/CNC/DNC machine tools, Classification of NC /CNC
machine tools, Advantage, disadvantages of NC /CNC machine tools, Application
of NC/CNC Part programming: CNC programming and introduction, Manual part
programming: Basic (Drilling, milling, turning etc.), Special part programming,
Advanced part programming, Computer aided part programming (APT)
Introduction: Automation in production system principles and strategies of
automation, basic Elements of an automated system. Advanced Automation
functions. Levels of Automations, introduction to automation productivity Control
Technologies in Automation: Industrial control system. Process industry vs
discrete manufacturing industries. Continuous vs discrete control. Continuous
process and its forms. Other control system components.

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 Course Outcomes

1. Learn what Advanced/Additive manufacturing (AM) is and understand why it has become one of the most
important technology trends in decades for product development and innovation

2. Demonstrate comprehensive knowledge of the broad range of AM processes, devices, capabilities and
materials that are available.
3. Understand the various software tools, processes and techniques that enable advanced/additive
manufacturing and personal fabrication

4. Learn how to create physical objects that satisfy product development/prototyping requirements, using
advanced/additive manufacturing devices and processes. Articulate the various tradeoffs that must be made in
selecting advanced/additive manufacturing processes, devices and materials to suit particular product
requirements.
5. Opportunity to design, engineer and fabricate an actual multi-component object using advanced/additive
manufacturing devices and processes and Understand the latest trends and business opportunities in AM,
distributed manufacturing and mass customization.

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 COURSE DESCRIPTION

In this course you will learn the importance of additive manufacturing ( 3D

Printing) and its huge role in global product development and innovation.
You will develop a rich knowledge of 3D printing technologies, devices,
capabilities, materials and applications.
You will learn the trade-offs between various 3D printing processes and
technologies, along with the various related software tools, processes and
techniques, such as 3D scanning, injection molding and casting.
You will explore the broad range of 3D printing applications, including
biomedical, aerospace, consumer products, and creative artistry, to mention a
few.
And finally, you will learn the latest trends and opportunities in 3D printing,
localized services, production parts, mass customization, and how to
commercialize your ideas.
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 Definition

Additive Manufacturing (AM) refers to a

process by which digital 3D design data is
used to build up a component in layers by
depositing material

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Additive Manufacturing (AM) is an appropriate name to describe the
technologies that build 3D objects by adding layer-upon-layer
of material, whether the material is plastic, metal, concrete or one
day…..human tissue.
Common to AM technologies is the use of a computer, 3D modeling
software (Computer Aided Design or CAD), machine equipment and
layering material.
Once a CAD sketch is produced, the AM equipment reads in data
from the CAD file and lays downs or adds successive layers
of liquid, powder, sheet material or other, in a layer-upon-layer fashion
to fabricate a 3D object.
 The term AM encompasses many technologies including subsets
like 3D Printing, Rapid Prototyping (RP), Direct Digital Manufacturing
(DDM), layered manufacturing and additive fabrication.

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 3D Printing Vs CNC Machining
The key difference between 3D printing and CNC machining is that
3D printing is a form of additive manufacturing, while the CNC
machining is subtractive.

This means CNC machining starts with a block of material (called a

blank), and cuts away material to create the finished part. To do this,
cutters and spinning tools are used to shape the piece.

Some advantages of CNC machining include great dimensional

accuracy as well as many compatible materials, including wood,
metals and, plastic

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 Both 3D printing and CNC machining are compatible
with a wide variety of materials, including both plastics
and metals.

 3D printing however is more focused on plastics overall,

though this is changing rapidly as better and more
affordable ways of 3D printing metal are being developed
by manufacturers such as 3D Systems, Arcam, Desktop
Metal and Markforged.

 The most commonly used plastics used in CNC include

ABS(Acrylonitrile butadiene styrene), Nylon (PA66),
Polycarbonate (PC), Acrylic (PMMA), Polypropylene (PP).
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A very commonly used metal in CNC machining is aluminium, used by
prototyping companies to create high-quality prototypes in a variety of
industries.

Aluminium is recyclable, has good protective qualities, and can create

effective prototypes for machining. Other commonly used metals include
stainless steel, magnesium alloy, zinc alloy titanium, and brass.

In 3D printing, commonly used thermoplastics include ABS(Acrylonitrile

butadiene styrene), PLA ( Polylactic acid), Nylon, ULTEM, but also photo-
polymers such as wax, calcinable or biocompatible resins.
Some niche 3D printers also allow for the printing of parts in sand,
ceramics, and even living materials.

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The most common metals used in 3D printing include
aluminium, stainless steel, titanium, and inconel.
It is also worth noting that to 3D print metal,
expensive ($100,000+) industrial machines are
required. Some materials such as super alloys or TPU
(flexible material) cannot be created with CNC, so must
be used with 3D printing or rapid tooling technology.

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 Different thermoplastics

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1. CAD
2. STL convert
3. File transfer to machine 4 Machine setup
4. Machine shop set up
5. Build
6. Remove
7. Post-process
8. Application

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 Step 1: CAD

All AM parts must start from a software model that fully describes
the external geometry. This can involve the use of almost any
professional CAD solid modeling software, but the output must be
a 3D solid or surface representation

Reverse engineering equipment (e.g., laser scanning) can also be

used to create this representation.

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 Step 2: Conversion to STL

Nearly every AM machine accepts the STL file format,

which has become a de facto standard, and nearly every
CAD system can output such a file format.

This file describes the external closed surfaces of the

original CAD model and forms the basis for calculation
of the slices.

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 Step 3: Transfer to AM Machine and STL File Manipulation

The STL file describing the part must be transferred to

the AM machine.

Here, there may be some general manipulation of the file

so that it is the correct size, position, and orientation for
building.

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 Step 4: Machine Setup

The AM machine must be properly set up prior to the build

process.

Such settings would relate to the build parameters like the

material constraints, energy source, layer thickness,
timings, etc.

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 Step 5: Build

Building the part is mainly an automated process and the

machine can largely carry on without supervision.

Only superficial monitoring of the machine needs to take

place at this time to ensure no errors have taken place like
running out of material, power or software glitches, etc.

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 Step 5: Build

Building the part is mainly an automated process and the machine

can largely carry on without supervision.

Only superficial monitoring of the machine needs to take place at this

time to ensure no errors have taken place like running out of
material, power or software glitches, etc.

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 Step 6: Removal

Once the AM machine has completed the build, the parts

must be removed.

This may require interaction with the machine, which may

have safety interlocks to ensure for example that the
operating temperatures are sufficiently low or that there are
no actively moving parts.

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 Step 7: Post processing

Once removed from the machine, parts may

require an amount of additional cleaning up
before they are ready for use. Parts may be weak
at this stage or they may have supporting features
that must be removed. This therefore often
requires time and careful, experienced manual
manipulation.

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 Step 8: Application

Parts may now be ready to be used. However, they may

also require additional treatment before they are acceptable
for use.

For example, they may require priming and painting to give

an acceptable surface texture and finish. Treatments may
be laborious and lengthy if the finishing requirements are
very demanding.

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 Advantages of AM

Freedom of design
Complexity for free
Potential elimination of tooling
Lightweight design
Elimination of production steps

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 Applications of AM

AM has been used across a diverse array of

industries, including;

 Automotive
 Aerospace
 Biomedical
 Consumer goods and many others

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 Classification of Additive Manufacturing Systems

The Better way is to classify AM systems broadly by the initial form of its material, all AM
Systems can be easily categorised into
Liquid Based
Solid Based
Powder Based

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Photo Polymerization (Stereolithography)

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 Photo Polymerization

• Stereolithography Apparatus (SLA) is a liquid-based process which builds parts directly from CAD
software.
• SLA uses a low-power laser to harden photo-sensitive resin and achieve polymerization.
• The process begins with a 3D CAD file. The file is digitally sliced into a series of parallel horizontal
cross-sections which are then provided to a Stereolithography Apparatus (SLA) one at a time.
• A laser traces the cross-section onto a bath of photopolymer resin which solidifies the cross-section.
The part is lowered a layer thickness into the bath and additional resin is swept onto the surface.
• The laser then solidifies the next cross-section. This process is repeated until the part is complete.
Most parts are completed in a matter of hours, thereby defined as a "Rapid Prototype".

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 Discrete Particle Systems

• Discrete particles are normally powders that are generally graded into a relatively
uniform particle size and shape and narrow size distribution.
• The finer the particles the better, but there will be problems if the dimensions get too
small in terms of controlling the distribution and dispersion.

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Powder Bed Fusion Processes
Selective Laser Sintering(SLS)

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Powder Bed Fusion Processes

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 Powder Bed Fusion Processes

• Selective Laser Sintering (SLS), the most prominent of the powder bed fusion processes, was
originally developed at the University of Texas at Austin.
• In SLS a layer of powdered material is spread out and levelled over the top surface
of the growing structure.
• A laser then selectively scans the layer to fuse those areas defined by the geometry of the
cross-section; the laser energy also fuses layers together.
• The unfused material remains in place as the support structure. After each layer is
deposited, an elevator platform lowers the part by the thickness of the layer, and the next layer of
powder is deposited.
• When the shape is completely built up, the part is separated from the loose supporting
powder.

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 Solid Sheet Systems

• One of the earliest AM technologies was the Laminated Object Manufacturing (LOM) system
from Helisys, USA.
• This technology used a laser to cut out profiles from sheet paper, supplied from a continuous
roll, which formed the layers of the final part.
• Layers were bonded together using a heat-activated resin that was coated on one surface of the
paper. Once all the layers were bonded together the result was very much like a wooden block.

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 Laminated Object Manufacturing

• Laminated Object Manufacturing (LOM) is a process that combines additive

and subtractive techniques to build a part layer by layer.
• In this process the materials come in sheet form. The layers are bonded together by pressure
and heat application and using a thermal adhesive coating.
• A carbon dioxide laser cuts the material to the shape of each layer given the information of
the 3D model from the CAD and STL file.
• The advantages of this process are the low cost , no post processing and supporting structures
required, no deformation or phase change during the process, and the possibility of building large
parts.
• The disadvantages are that the fabrication material is subtracted thus wasting it, low
surface definition, the material is directional dependent for machinability and mechanical properties,
and complex internal cavities are very difficult to be built.
• This process can be used for models with papers, composites, and metals

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Laminated Object

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Manufacturing

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Advantages
• Ability to produce larger-scaled models.
• Uses very inexpensive paper
• Fast and accurate
• Good handling strength
• Environmentally friendly
• Not health threatening.
Disadvantages
• Need for decubing, which requires a lot of labor
• Can be a fire hazard
• Finish, accuracy and stability of paper objects not as good as materials used with
other RP methods
Typical Uses
• Investment casting patterns
• Concept verification
• Masters for silicone-rubber injection tools
• Fit-check
• Direct use

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 Molten Material Systems

• Molten material systems are characterized by a pre-

heating chamber that raises the
materialtemperature to melting point so that it can flow
through a delivery system.

The most well -known method for doing this is the Fused Deposition Modeling (FDM)
material extrusion technology developed by the US company Stratasys

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 Fused Deposition Modeling

• FDM is a filament-based technology where a temperature-controlled head extrudes a

thermoplastic material layer by layer onto a build platform.
• A support structure is created where needed and built in a water-soluble material.

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Application areas
Prototypes are produced for form / fit and functional testing in standard materials by
FDM
Support parts (jigs, fixtures, helps) can be produced directly
Small series parts down to one of a kind are built in standard materials by fused
deposition modeling

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 Post processing of AM parts

• Post-processing is an essential stage of additive manufacturing. It‟s the last step in the
manufacturing process, where parts receive finishing touches such as smoothing and painting.
• Why is post-processing important?
• Post-processing improves the quality of parts and ensures that they meet their design
specifications.
• The finishing process can enhance a parts surface characteristics, geometric accuracy,
aesthetics, mechanical properties, and more. For samples and prototypes, this can mean the
difference between a sale or a loss.
• For production parts, finishing creates a part that is ready to use.

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• A metal additive manufacturing (AM) part is essentially “welded” to the build plate, and
you will not be able to pull it off without some assistance. Even then, the AM part will need post
processing before it is ready to use.
• Here are some costs associated with post processing AM parts

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 Powder Removal:

• AM parts build “down” in a powder-bed fusion system as new layers are added to the top, which
means that parts are buried in powder when they are done .
• After the build has finished and the parts/build plate have cooled, the machine operator
has to remove all of the powder
• from the build volume and sieve/filter/recycle it for later use, assuming you want to reuse it.
• This is not an expensive step, but it does take time.

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 Stress Relief:

• The heating and cooling of the metal as the part builds layer-by-layer leads to internal stresses
that must be relieved before the part is removed from the build plate. Otherwise, the part may warp or
even crack.
• Stress-relieving the part requires an oven or furnace (preferably with environmental
controls) that is big enough to fit the entire build plate.
• Many recommend using an oven with an inert environment to minimize oxidation on the part
surface.

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 Part Removal:

• Most companies use wire EDM to remove parts from the build plate, however many machine
shops are starting to use a bandsaw because it is faster and the bottoms of the parts must be finished
anyway.
• Keep in mind that materials such as Inconel strain-harden as they are worked, making it
difficult to remove them from the build plate with just a bandsaw.
• A bandsaw can complete the task in minutes.

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 Heat Treatment:

• Heat treatment (aging, solution annealing and so on) improves the microstructure and
mechanical properties of the parts and is necessary for nearly all AM parts.
• In many cases, this step also requires an environmentally controlled furnace with the ability to
regulate the temperature and cool -down schedule.
• Heat treatment may affect the dimensions of the parts, so most people prefer to heat-treat parts
before they machine/finish them.
• The American Society for Testing and Materials (ASTM) just released a standard for thermal
postprocessing of metal AM parts.

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 Machining:
• Machining of mating interfaces, surfaces, threads, support structures
and more likely will be required to ensure dimensional accuracy of the finished
part.
• Few AM parts meet specifications “as built,” and if nothing else,
the surface of the part that was connected to the build plate will need to be
finished.
• Most manufacturing companies already have machining systems on
hand, but registering parts and establishing datums for machining can be
tricky, especially for complex, organically shaped parts made with AM.
• Accessing internal channels or cooling passages that need to be
machined can also increase costs. The cost here is highly dependent on the
material and the job as well as the fixturing needed to hold the part.

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 Surface Treatments:

• Surface finishing also might be required

to improve surface finish/quality, reduce surface
roughness, clean internal channels or remove partially melted
particles on a part.
• When outsourced, these costs can easily run in the hundreds
if not thousands of dollars.

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 Inspection and Testing:

• Metrology, inspection and nondestructive testing using white/blue -

light scanning, dye-penetrant testing, ultrasonic testing, computed
tomography (CT) scanning and more will be needed after post processing and
possibly at multiple points during post processing.
• Destructive testing of sample parts and analysis of witness coupons
(for example, tensile bars), powder chemistry, material microstructure and
more also may be needed to gather data to help with process qualification
and ultimately part certification.
• Most companies will have a range of metrology and non- destructive
testing methods on hand, but AM parts with internal channels, lattice
structures and other internal enhancements may require CT scanning to
ensure clear passageways, evaluation of internal geometries and more.

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 Guidelines for process selection
• A variety of AM technologies have been developed. According to
ASTM Standard F2792 (ASTM F2792-12a 2012), these technologies can be
catalogued into seven groups: binder jetting, directed energy deposition,
material extrusion, material jetting, powder bed fusion, sheet lamination
and vat photo- polymerization.
• More than 350 industrial AM machines and 450 materials have been
identified in the market (Senvol LLC 2015). The debate about which
machine or technology fares better than others has little value as each of
them has its targeted applications.
• AM technologies are no longer limited to prototyping usage,
but are increasingly also being used for making end products .
• Therefore, „Design for Additive Manufacture‟ (DfAM) becomes
increasingly significant for avoiding potential manufacturing pitfalls and
maximizing utilization of AM capability.

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 The commonly used decision process can be described by a
six-stage sequential decision-making model as proposed

• Identification of the problem

• Obtaining necessary information
• Production of possible solutions
• Evaluation of such solutions
• Selection of a strategy for performance
• Implementation and subsequent learning and reformulation

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 AM Applications

1. Rapid Prototyping
• Models and parts for research purposes can be easily manufacture
whenever required. Easy to make changes in the models as per the research
proceedings.
2. Food
• Cornell Creative Machines Lab is making food items such as chocolates,
candy, pasta, pizza using 3D printing technique since 2012.
3. Apparel
• Products such as customize shoes, clothes and eye wears are being
manufactured. •Nike is using 3D printing to manufacture the “Vapor Laser
Talon” football shoe for players of American football

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4. Vehicle
• In 2010 Urbee became the first car whose whole body was 3D
printed (by US engineering group Kor Ecologic and the company Stratasys ).
• In early 2014, Swedish supercar manufacturer, Koenigsegg
,manufactured a supercar having many 3D printed mechanical
parts in it.
5. Firearms
Defense arms such as guns, rifles and safety equipment has also been
manufacture by AM.
In 2012 US based group “Defense Distributed”, designed a working plastic
gun that could be downloaded and reproduced by anybody with a 3D printer.
In 2013, „Solid Concepts‟, based in Austin, Texas, US Asucceeded
in manufacturing first working metal gun.

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6. Medical
• •Nowadays medical devices, specific implants, hearing aids, dental
products and pills are being manufacture by AM. •During October 2014, a five
year old girl born without fully formed fingers on her left hand
• became the first child in the UK to have a prosthetic hand made with
3D printing . Till now more than 400 hands have been transplanted by E-
NABLE.
• •In august 2015, US FDA (Food and Drug administration) approved
3D printed pills which allows very porous pills to be produced, which enables
high drug doses in a single pill which dissolves quickly and can be ingested
easily.
• Currently, active research is pursued by different groups to use cells and
biomaterials by different print-heads to produce organs on demand. This might
answer the organ shortage scenario in regenerative medicine application.”

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7. Bioprinting
• Bioprinting refers to manufacturing artificial biological organs and body
parts capable of working like original ones.
• In this process, layers of living cells are deposited onto a gel medium or sugar
matrix and slowly built up to form three dimensional structures including vascular systems.
• The first production system for 3D tissue printing was delivered in 2009, based on
NovoGen bio -printing technology. •In 2013, Chinese scientists began printing ears, livers
and kidneys,with living tissue.•In 2014, researchers at the University of Hasselt, in Belgium
had successfully printed a new jawbone for an 83 year old woman.
8. Space
• In September 2014, “SpaceX” delivered the first zero gravity 3D printer to the
International Space Station (ISS).
• In December 2014, NASA emailed CAD drawings for a socket wrench to
astronauts aboard the ISS, who then printed the tool using its 3D printer.
• The European Space Agency plans to deliver its new advance Portable On
Board 3D Printer to the International Space Station by the end of 2015

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 Assignment questions

• Define additive manufacturing(AM)?

• Distinguish between AM and CNC.
• List applications and advantages of CNC.
• List and explain stages of AM.
• Classify AM Process, explain any one in each processes.
• Explain post-processing of AM part.
• Explain guideline for process selection.
• Explain applications of AM in different areas.

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MVJ College of Engineering
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Bangalore-560 067
E-mail:
Thank You
[email protected]
Ph: +91 8073533599

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