Table Of ContentAdditive Manufacturing
Fundamentals and Advancements
Additive Manufacturing
Fundamentals and Advancements
Manu Srivastava, Sandeep Rathee,
Sachin Maheshwari and T. K. Kundra
CRC Press
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Library of Congress Cataloging- in-Publication Data
Names: Srivastava, Manu, author. | Rathee, Sandeep, author. | Maheshwari,
Sachin, author. | Kundra, T. K., author.
Title: Additive manufacturing : fundamentals and advancements / by Manu
Srivastava, Sandeep Rathee, Sachin Maheshwari, and T.K. Kundra.
Description: Boca Raton, FL : CRC Press/Taylor & Francis Group, 2019. |
Includes bibliographical references. | Summary: “There is a growing need
for manufacturing optimization all over the world, and the immense market
of Additive Manufacturing (AM) technologies proves dictates a need for a
book that will provide knowledge of the various aspects of AM for anyone
interested in learning about this fast growing topic. This book will
disseminate knowledge of AM amongst scholars at graduate level, post
graduate level, doctoral level, as well as industry personnel. The objective is
to offer a state-of-the-art book which covers all aspects of AM and
incorporates all information regarding trends, history, principles, limitations
and advancements in a one-stop resource”– Provided by publisher.
Identifiers: LCCN 2019020277 | ISBN 9781138485457 (hardback : acid-free
paper) | ISBN 9781351049382 (ebook)
Subjects: LCSH: Three-dimensional printing. | Manufacturing processes.
Classification: LCC TS171.95 .S73 2019 | DDC 621.9/88–dc23
LC record available at https://lccn.loc.gov/2019020277
Visit the Taylor & Francis Web site at
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Contents
List of Figures ......................................................................................................xiii
List of Tables ........................................................................................................xix
List of Abbreviations ..........................................................................................xxi
Preface ..................................................................................................................xxv
Summary ............................................................................................................xxix
Acknowledgments ............................................................................................xxxi
About the Authors ..........................................................................................xxxiii
Section A General Details of Additive Manufacturing
Processes ............................................................................................1
1. Introduction .....................................................................................................3
1.1 Introduction ...........................................................................................3
1.2 Types of AM Technologies...................................................................3
1.3 Nomenclature of AM Machines .........................................................4
1.4 Prototyping, Tooling and Manufacturing .........................................5
1.4.1 Direct AM Processes ...............................................................6
1.4.1.1 Direct Prototyping ...................................................6
1.4.1.2 Direct Tooling ...........................................................6
1.4.1.2.1 Prototype Tooling .................................7
1.4.1.3 Direct Manufacturing ..............................................7
1.4.2 Indirect AM Processes ............................................................7
1.4.2.1 Indirect Prototyping ................................................8
1.4.2.2 Indirect Tooling ........................................................8
1.4.2.3 Indirect Manufacturing ...........................................8
1.5 Advantages of AM Processes ..............................................................9
1.6 Challenges of AM Processes .............................................................10
1.7 Summary ..............................................................................................11
2. Comparison of Additive Manufacturing with Conventional
Manufacturing Processes ............................................................................13
2.1 Introduction .........................................................................................13
2.2 Comparison between AM and Conventional
Manufacturing.....................................................................................14
2.2.1 Comparison between AM and CNC Machining ..............14
2.2.2 Comparison between AM and Deformation
Processes .................................................................................16
2.2.3 Comparison between AM and Primary or Shaping
Processes .................................................................................18
v
vi Contents
2.3 Pros and Cons of AM with Respect to Conventional
Manufacturing.....................................................................................18
2.3.1 Part Flexibility ........................................................................19
2.3.2 Waste Prevention ...................................................................19
2.3.3 Production Flexibility ............................................................20
2.3.4 Process Running Cost ...........................................................20
2.3.5 Probability of Change ...........................................................20
2.3.6 Start- up Investment ...............................................................20
2.3.7 Mass Production ....................................................................20
2.3.8 Raw Material ..........................................................................20
2.4 Summary ..............................................................................................21
3. Additive Manufacturing Processes ..........................................................25
3.1 Introduction .........................................................................................25
3.2 Classification of AM Processes .........................................................26
3.3 Common AM Processes .....................................................................31
3.4 Summary ..............................................................................................31
4. Evolution of Additive Manufacturing Technologies ............................39
4.1 Introduction .........................................................................................39
4.2 Evolution of AM Technologies ..........................................................40
4.3 Timeline of AM Technology ..............................................................41
4.4 Summary ..............................................................................................47
5. Generalized Additive Manufacturing Process Chain ..........................51
5.1 Introduction .........................................................................................51
5.2 AM as Fundamental Time Compression Engineering
(TCE) Element ......................................................................................51
5.3 AM Data and Information Flow .......................................................53
5.4 Generalized AM Process Chain and Eight Steps in AM ..............54
5.5 Variation from One AM Machine to Another ................................57
5.6 Maintenance of Equipment ...............................................................58
5.7 Material Handling Issues ...................................................................58
5.8 Summary ..............................................................................................58
Section B Process Specific Details of Various Additive
Manufacturing Processes .............................................................61
6. Additive Manufacturing Processes Utilizing Vat
Photopolymerization ...................................................................................63
6.1 Introduction .........................................................................................63
6.2 Materials ...............................................................................................64
6.2.1 Precursors ...............................................................................64
Contents vii
6.2.2 Photoinitiators ........................................................................65
6.2.3 Absorbers ................................................................................65
6.2.4 Filled Resins ............................................................................65
6.2.5 Additives .................................................................................66
6.2.6 Post- Processing .......................................................................66
6.3 Photopolymerization Process ............................................................66
6.4 Process Modelling ...............................................................................68
6.5 Variants and Classification of Vat Photopolymerization
Process ..................................................................................................69
6.5.1 Free and Constrained Surface Approaches........................74
6.5.2 Laser- SLA ................................................................................75
6.5.2.1 Two Photon Photopolymerization (TPP) ............75
6.5.2.2 Pinpoint Solidification ...........................................75
6.5.2.3 Bulk Lithography ...................................................75
6.5.3 Digital Light Processing SLA Process (DLP- SLA) .............76
6.5.3.1 Continuous Liquid Interface Production ............77
6.5.4 Liquid Crystal Display Stereolithography .........................78
6.6 Advantages and Limitations of Vat Photopolymerization
Processes ..............................................................................................78
6.7 Summary ..............................................................................................79
7. Additive Manufacturing Processes Utilizing Powder Bed
Fusion Technique ..........................................................................................81
7.1 Introduction .........................................................................................81
7.2 Materials ...............................................................................................81
7.3 Powder Fusion Mechanism ...............................................................83
7.4 Process Parameters and Modelling ..................................................84
7.4.1 Processing Temperatures (T ) ...................................85
Processing
7.4.2 Total Free Energy (E) ............................................................85
s
7.4.3 Surface Area Bed/Volume Ratio of Particle (SA /
bed
VR ) ...................................................................................86
particle
7.4.4 Particle Dimensions ...............................................................86
7.4.5 Raw Material Thermal Properties .......................................86
7.5 Powder Handling ................................................................................86
7.6 Powder Fusion Techniques ................................................................87
7.6.1 Solid State Sintering...............................................................87
7.6.2 Chemical Sintering ................................................................88
7.6.3 Complete Melting ..................................................................89
7.6.4 Liquid Phase Sintering/Partial Melting .............................89
7.6.5 Indirect Processing ................................................................89
7.6.6 Pattern Method.......................................................................90
7.6.7 Direct Sintering ......................................................................90
7.7 Powder Bed Fusion Process Variants ...............................................90
7.7.1 Low Temperature Laser- Based Processing ........................91
7.7.2 Metal and Ceramic Laser- Based Systems ..........................92
viii Contents
7.7.3 Electron Beam Melting ..........................................................93
7.7.4 Line- and Layer- Wise Systems .............................................94
7.8 Strengths and Weaknesses of PBF- based AM techniques ............95
7.9 Summary ..............................................................................................96
8. Additive Manufacturing Processes Utilizing an
Extrusion- Based System ..............................................................................99
8.1 Introduction .........................................................................................99
8.2 Basic Principles of Extrusion- Based Processes ...............................99
8.3 Fused Deposition Modelling ...........................................................101
8.3.1 FDM Materials ......................................................................101
8.3.2 Working Principles of FDM ................................................102
8.3.3 FDM Process Parameters ....................................................103
8.3.4 Performance Measures ........................................................105
8.3.5 FDM Modellers ....................................................................106
8.3.6 FDM Limitations ..................................................................106
8.4 Bio- Extrusion .....................................................................................109
8.5 Contour Crafting ...............................................................................109
8.6 Non- Planar Systems..........................................................................110
8.7 RepRap FDM Systems ......................................................................110
8.8 Fab@home FDM Systems ................................................................111
8.9 Applications .......................................................................................111
8.10 Summary ............................................................................................113
9. Additive Manufacturing Processes Utilizing
Material Jetting ...........................................................................................117
9.1 Introduction .......................................................................................117
9.2 Variants of Material Jetting..............................................................118
9.3 Multi- Jet Printing ..............................................................................118
9.4 Droplet Formation Techniques .......................................................119
9.4.1 Continuous Stream Inkjet Technology .............................120
9.4.2 Drop- on-Demand Inkjet Technology ...............................122
9.5 Materials for Material Jetting ..........................................................123
9.6 Advantages, Drawbacks and Applications of
Material Jetting ..................................................................................124
9.6.1 Advantages of MJ ....................................................................124
9.6.2 Drawbacks of MJ .....................................................................125
9.6.3 Applications of MJ ...................................................................126
9.7 Design and Quality Aspects ...........................................................127
9.8 Summary ............................................................................................127
10. Additive Manufacturing Processes Utilizing Binder Jetting ............131
10.1 Introduction .......................................................................................131
10.2 Process Description ..........................................................................132
10.3 Raw Materials ....................................................................................134
Contents ix
10.4 Design and Quality Aspects of BJ ..................................................134
10.4.1 Process Related Parameters ................................................134
10.4.2 Material Related Parameters ..............................................136
10.5 Advantages of Binder Jetting ..........................................................140
10.6 Drawbacks of Binder Jetting ............................................................141
10.7 Applications of Binder Jetting .........................................................141
10.8 Summary ............................................................................................142
11. Additive Manufacturing Processes Utilizing Sheet
Lamination Processes ................................................................................145
11.1 Introduction .......................................................................................145
11.2 Variants of Sheet Lamination ..........................................................145
11.3 Laminated Object Manufacturing ..................................................146
11.3.1 Process Description .............................................................146
11.3.2 Materials for LOM ...............................................................148
11.3.3 Process Variants of LOM ....................................................148
11.3.4 Advantages of LOM .............................................................148
11.3.5 Drawbacks of LOM ..............................................................145
11.3.6 Design and Quality Aspects ..............................................149
11.3.7 Applications of LOM ...........................................................149
11.4 Ultrasonic Consolidation .................................................................150
11.4.1 Benefits of UAM ...................................................................152
11.4.2 Drawbacks of UAM .............................................................152
11.4.3 Applications of UAM ...........................................................153
11.5 Summary ............................................................................................153
12. Additive Manufacturing Processes Utilizing Directed
Energy Deposition Processes ...................................................................155
12.1 Introduction .......................................................................................155
12.2 Variants of Directed Energy Deposition ........................................156
12.3 Process Description ..........................................................................157
12.4 Classification of DED Techniques ...................................................158
12.4.1 Laser- Based DED Techniques ................................................158
12.4.1.1 Direct Laser Deposition.......................................158
12.4.1.1.1 Process Parameters of DLD .............158
12.4.1.1.2 Laser- Based DED Techniques
for 2D Geometries .............................159
12.4.1.1.3 Laser- Based DED Techniques
for 3D Geometries .............................159
12.4.1.1.4 Applications of Laser Based DED
(LB- DED) ............................................162
12.4.2 Electron Beam- Based DED Processes ...............................164
12.5 Advantages of DED...........................................................................165
12.6 Drawbacks of DED ............................................................................165
12.7 Summary ............................................................................................165
