Additive Manufacturing, Second Edition

485 Pages·2019·105.575 MB·\485

by  Amit Bandyopadhyay (Editor), Susmita Bose (Editor)

Additive Manufacturing
Second Edition

Additive Manufacturing

Second Edition
Edited by
Amit Bandyopadhyay
Susmita Bose
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2020 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
International Standard Book Number-13: 978-1-138-60925-9 (Hardback)
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts
have been made to publish reliable data and information, but the author and publisher cannot assume
responsibility for the validity of all materials or the consequences of their use. The authors and publishers
have attempted to trace the copyright holders of all material reproduced in this publication and apologize
to copyright holders if permission to publish in this form has not been obtained. If any copyright material
has not been acknowledged please write and let us know so we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced,
transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or here-
after invented, including photocopying, microfilming, and recording, or in any information storage or
retrieval system, without written permission from the publishers.
For permission to photocopy or use material electronically from this work, please access www.copyright.
com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood
Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and
registration for a variety of users. For organizations that have been granted a photocopy license by the
CCC, a separate system of payment has been arranged.
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are
used only for identification and explanation without intent to infringe.
Library of Congress Control Number: 2019949036
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the CRC Press Web site at
http://www.crcpress.com
Contents
Preface......................................................................................................................vii
Editors .......................................................................................................................ix
Contributors ..............................................................................................................xi
Chapter 1 Introduction to Additive Manufacturing ..............................................1
Amit Bandyopadhyay, Thomas Gualtieri, Bryan Heer,
and Susmita Bose
Chapter 2 Additive Manufacturing of Polymers .................................................25
Amit Bandyopadhyay, Kellen D. Traxel, Caitlin Koski,
and Susmita Bose
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Chapter 3 Additive Manufacturing Technologies for Polymers and
Boca Raton, FL 33487-2742
Composites .........................................................................................43
© 2020 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business Ranji Vaidyanathan
No claim to original U.S. Government works
Chapter 4 Additive Manufacturing of Metals Using Powder Bed-Based
International Standard Book Number-13: 978-1-138-60925-9 (Hardback)
Technologies .......................................................................................93
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts
have been made to publish reliable data and information, but the author and publisher cannot assume M. J. Mirzaali, F. S. L. Bobbert, Y. Li, and A. A. Zadpoor
responsibility for the validity of all materials or the consequences of their use. The authors and publishers
have attempted to trace the copyright holders of all material reproduced in this publication and apologize
to copyright holders if permission to publish in this form has not been obtained. If any copyright material Chapter 5 Deposition-Based and Solid-State Additive Manufacturing
has not been acknowledged please write and let us know so we may rectify in any future reprint. Technologies for Metals ...................................................................147
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, Vamsi Krishna Balla
transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or here-
after invented, including photocopying, microfilming, and recording, or in any information storage or
retrieval system, without written permission from the publishers.
Chapter 6 Additive Manufacturing of Ceramics...............................................183
For permission to photocopy or use material electronically from this work, please access www.copyright.
Susmita Bose, Naboneeta Sarkar, Sahar Vahabzadeh,
com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood
Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and Dongxu Ke, and Amit Bandyopadhyay
registration for a variety of users. For organizations that have been granted a photocopy license by the
CCC, a separate system of payment has been arranged.
Chapter 7 Designing for Additive Manufacturing ............................................233
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are
used only for identification and explanation without intent to infringe. Timothy W. Simpson
Library of Congress Control Number: 2019949036
Chapter 8 Multifunctional Printing: Incorporating Electronics into 3D
Parts Made by Additive Manufacturing ...........................................269
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com Dishit Paresh Parekh, Denis Cormier, and Michael D. Dickey
and the CRC Press Web site at
http://www.crcpress.com
v
vi Contents
Chapter 9 Industrial Implementation of Additive Manufacturing ....................317
Edward D. Herderick and Clark Patterson
Chapter 10 Additive Manufacturing for the Space Industry ..............................333
Christian Carpenter
Chapter 11 Bioprinting—Application of Additive Manufacturing in
Medicine .......................................................................................355
Forough Hafezi, Can Kucukgul, S. Burce Ozler,
and Bahattin Koc
Chapter 12 Additive Manufacturing in Materials Innovation ............................377
Mitun Das and Vamsi Krishna Balla
Chapter 13 Personalized Implants and Additive Manufacturing .......................421
Mukesh Kumar and Bryan Morrison
Chapter 14 Teaching Additive Manufacturing Concepts to Students and
Professionals .....................................................................................439
Amit Bandyopadhyay, Yanning Zhang, and Susmita Bose
Chapter 15 Additive Manufacturing: The Future of Manufacturing
in a Flat World ..................................................................................451
Susmita Bose and Amit Bandyopadhyay
Index ......................................................................................................................463
Preface
The field of additive manufacturing is seeing an explosive growth in recent years
due to renewed interest in manufacturing in the United States and other parts of the
world. The experience of drawing something in a computer and then see that part
being printed in a 3D printer, which can be touched or felt, is still fascinating to
many of us. Now we are seeing the same in our kids who are only in their middle
school or high school and experience the revolution of additive manufacturing/3D
printing through their own creation. Such transformative change in our society is
only possible due to significant reduction in the price of various 3D printers. Even a
few years back, a good 3D printer was more than $50,000 in the United States. Due
to the high cost of 3D printers, the majority of our population was only able to see
a picture or a video of different 3D printers. As the cost of the printer came down
below $1000, most businesses, universities and schools now have some kind of 3D
printers, which allows many people to explore and innovate with this fascinating
technology. Therefore, we felt that our book will be quite timely where we have tried
to capture some of these fascinating developments using “3D Printing” or “Additive
Manufacturing” technologies.
We understand that there are a few other books in the market that deal with addi-
tive manufacturing in some form. When we reviewed the landscape, we realized
that majority of those books are developed with greater emphasis on mechanical
engineering aspects. However, at present, most of the printing technology is quite
mature and majority of the innovation is coming in the areas of materials develop-
ment, related critical issues and their applications. Therefore, we have focused our
work more in the applications of additive manufacturing than the core 3D printing
technologies. Our hope is that the reader will be able to see how these technologies
are currently being used and then contribute to the field with their own innovation.
We have designed the book in a way that can also be used in a class room setting.
The first few chapters are focused on different additive manufacturing technolo-
gies based on various materials that are typically used. Then we discuss some of
the application areas where additive manufacturing is making a significant impact.
Finally, some discussions on educational aspects and regulatory issues have also
been added since those are becoming important as the additive manufacturing is
becoming a more mature technological platform in many industries. For this Second
Edition, we have more emphasis on design issues in additive manufacturing and new
information related to first-generation additive manufacturing processes for poly-
mers. We have also added suggested further reading materials and some questions
for educators if used as a textbook.
We like to thank all the authors for their contributions in this book. Without their
help our project would have never been completed. Also, without some sacrifice at
home from both our boys, Shohom and Aditya, we could not have completed this
work.
Even after working in this area for more than 20 years, we still learn new things
regularly related to applications of additive manufacturing. We hope that this book
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viii Preface
will be useful to many veteran researchers as well as those who are entering this field
now, and help them understand the subject better to contribute toward their work,
which can make a positive difference in our society.
Amit Bandyopadhya and Susmita Bose
Pullman, WA, USA
September 2019
Editors
Amit Bandyopadhyay, the Herman and Brita Lindholm Endowed Chair Professor
in the School of Mechanical and Materials Engineering at Washington State
University (WSU), received his BS in metallurgical engineering from Jadavpur
University (Kolkata, India) in 1989, MS in metallurgy from the Indian Institute of
Science (Bangalore, India) in 1992, and PhD in materials science and engineer-
ing from the University of Texas at Arlington (Arlington, TX) in 1995. In 1995, he
joined the Center for Ceramic Research at Rutgers University for his postdoctoral
training. In 1997, he joined WSU as an assistant professor, promoted to an associ-
ate level in 2001, and to the full professor level in 2006. His research expertise is
focused on additive manufacturing of hard materials toward structural and biomedi-
cal applications. He has communicated over 300 technical articles, inventor of 19
issued patents, edited 10 books, and has supervised over 40 graduate students for
their degrees in physics, mechanical engineering, and materials science and engi-
neering. Among others, Professor Bandyopadhyay received the CAREER award
from the US National Science Foundation, and the Young Investigator Program
award from the US Office of Naval Research. Professor Bandyopadhyay is a fel-
low of the US National Academy of Inventors, the American Ceramic Society, the
American Society for Materials, the American Institute for Medical and Biological
Engineering, the American Association for the Advancement of Science, Society
for Manufacturing Engineers, and the Washington State Academy of Sciences. His
work has been cited over 17,000 times and the current “H” index is >69 (Google
Scholar, 09/2019).
Susmita Bose is Herman and Brita Lindholm Endowed Chair Professor in the School
of Mechanical and Materials Engineering (MME) at Washington State University.
Professor Bose received her BS from Kalyani University (India), MS from the Indian
Institute of Technology (IIT)—Kanpur, and PhD from Rutgers University (NJ, USA)
in 1998 in Physical Organic Chemistry. Since 1998, she is working with 3D printing of
bone tissue engineering scaffolds with controlled chemistry, especially with calcium
phosphates, surface modification of metallic implants, and drug delivery. In 2001, she
started as an assistant professor in MME, promoted to associate professor in 2006,
and to full professor in 2010. Her awards include the Presidential Early Career Award
for Scientist and Engineers (PECASE, the highest honor given to a young scientist by
the US President at the White House) award from the National Science Foundation,
the Schwartzwalder-Professional Achievement in Ceramic Engineering award, and
Richard M. Fulrath award from the American Ceramic Society (ACerS). Prof. Bose
was named as Life Science Innovation Northwest Women to Watch Honoree by the
Washington Biotechnology and Biomedical Association. She has supervised over 40
graduate students, published over 250 technical papers, edited 9 books, and inventor
of 11 issued patents. Her research papers have been cited over 16,000 times (“H” index
68, Google Scholar, 09/2019). Dr. Bose is a fellow of the Materials Research Society,
US National Academy of Inventors, the American Society for Materials, the American
ix