ADDITIVE MANUFACTURING
Course Code: MF8071
Department of Mechanical Engineering
Ramco Institute of Technology, Rajapalayam
TEXT BOOKS:
1 Chua C.K., Leong K.F., and Lim C.S., “Rapid prototyping: Principles and applications”, Third
edition, World Scientific Publishers, 2010.
2 Ian Gibson, David [Link], Brent Stucker “Additive Manufacturing Technologies: Rapid
Prototyping to Direct Digital Manufacturing” Springer , 2010.
REFERENCES:
1 Andreas Gebhardt “Understanding Additive Manufacturing: Rapid Prototyping, Rapid
Manufacturing”
Hanser Gardner Publication 2011.
2 Kamrani A.K. and Nasr E.A., “Rapid Prototyping: Theory and practice”, Springer, 2006.
3 Liou L.W. and Liou F.W., “Rapid Prototyping and Engineering applications :A tool box for
prototype
COURSE OUTCOME:
On completion of this course, students will learn about
Working principle and construction of Additive Manufacturing
technologies,
AM potential to support design and manufacturing,
Modern development in additive manufacturing process
Case studies relevant to mass customized manufacturing.
Flowchart of digital information to produce physical
models
STANDARDS
Advantages Of 3D Printing
1 No need for CNC Machining / Tooling / Die Creation
2 No limitations on complexity / creativity
3 Shorter time to market
4 Possibility of mass customization
5 Multi-material options
Limitations Of 3D Printing
1 3D Printing is a slow process
2 Surface finish issues, need post processing
3 Applicable only for smaller quantities
4 Limited by the types of input materials
5 Failure rate is still quite high
3D Printing vs. Traditional Manufacturing
Customization Intricate Parts Prototype Cost 1st Part Lead Time
10
9 9 9
7
5 5
4
Cost/Low volume Cost/High Volume Strength Surface Finish
10 10 10
9
8
7
2
3D Printing vs. Traditional Manufacturing
Cost Cost
Conventional Production Conventional Production
3D Printing 3D Printing
No. Of Pieces Complexity Of Pieces
Industries Implementing 3D Printing
Jewelry Health Care Research Fashion
Personalized Items Guides, Prosthetics High precision parts Dresses, Ornaments
Art Hobby/ Gifts Accessories Food
Unique toys, Sculptures Personalized Gifts Custom fit shoes… Various food items
Case Study 1 – Personal Memento
Step 1 : Concept Design Step 2 : Part Creation
Step 4 : Finishing Step 3 : Assembly
Case Study 2 – Industrial Layout
Step 1 : Aerial Survey Step 2 : Topography
Step 4 : Finishing Step 3 : Elements Printing
Case Study 3 – Fiber Mould Batch Production
Step 1 : Concept Step 2 : 3D Design
Step 4 : Batch Production Step 3 : 3D Print
An innovative case study for
the automotive industry
18
A cylinder head. An innovative solution for the
automotive industry
‘Lighter, complex and faster from design to
manufacturing than conventional production’
19
Everything start with the redesign to get the
most of the technology
20
Correct orientation, correct support structures
• Powder is less conductive than molten metal.
• So supports are built below massive zones to dissipate
the heat and avoid over-melting.
21
Part after removing supports
22
3D Scan comparison
23
More applications
24
Drillers AET-BMT
‘Smart drilling machines made of Titanium using EBM’
Why metal additive
manufacturing?
Production cycle reduced up to 70%
Maintenance cost reduced 80%
Save of weight: high strenght vs weight
ratio.
Integration of functions
25
Laser collimator: simplifying the assembly
and adding performance
26
Orthopedics, customized implants by Metal
additive manufacturing
‘Production of complex patient specific implants’
Play on porosity, roughness and randomness lattices to replicate bone
conditions and promote cell growth
picture: ARCAM
27
Examples of the AM course projects: a an typical designs of experiments and tests
and b
an exploratory test on new ideas
Routine AM topics and activities utilized in the Tool Design
class
Examples ofAMapplications in senior design projects: a NASA Mars core sampling system
project; b Centrifugal force mechanism; c Light holder designing and fabrication, d Luminaire
designing and fabrication, e Battery terminal cap prototyping followed by metallic mold design and
fabrication, and f Keychain design, fabrication, and casting
Additive manufacturing process development as Experiments and the fabrications of their parts
part of a senior design project: Heat element
status for the Selective Inhibition of the Sintering
AM process
Applying AM and other engineering tools in week-long
Different stages of reverse engineering,CADfile
engineering camps for K-12 students
improvement,AM, and face reconstruction needed to
identify the person
Student designs for AM geometry benchmarking
Project example for infill pattern effect for material extrusion AM
AM lightweight design project examples DFAM course semester design
project
Final evaluation competition of the semester project
Breakeven point analysis to replace the conventional
manufacturing of a structural mobile phone component in pre-
series production. Adapted from (Flores Ituarte et al. 2016b)
Cost development for increased build volume rates in
metal powder bed fusion systems
Simplified block design manifold showing only the Manifold design before and after shell operation on
required in and out channels block design
Support material required by shelled block design in two Example of a design that requires minimal
different print orientations support material
Examples of a course attendee manifold designs Original seat ‘OT’Arts’ made of wood by
Stratoconception (source Cirtes—Fabrication
Additive Dunod 2015)
Steel tooling for gravity casting with
advanced conforming cooling made
by Mould for casting made by sand sintering (source
Stratoconception (source Cirtes— CTIF—Fabrication Additive Dunod 2015)
Complete development phase of a part produced from the
mould made by sand sintering (source CTIF—Fabrication
Additive Dunod 2015)
Insert of mould with thermal regulation (source
PEP—Fabrication Additive Dunod 2015)
On the left: initial part; on the right: optimized
part (source Volume—Fabrication Additive
Dunod 2015)
Dental applications of vat
photopolymerisation (EnvisionTEC 2017)
Ekso Bionics suit (3D Systems 2017)
a Orthopaedic titanium implants b Dental cobalt implants (EOS
GmbH 2017)
Ankle/foot polymer orthosis (EOS 2017)
a Custom sculpt implant b Acetabular cups with integrated lattice structures
for improved osseointegration (Arcam EBM 2017)
a BioScaffolder 3.1 system b medical-grade PCL scaffold to reconstruct the shape and volume of a
female breast after mastectomy c human cells printed onto an alginate/hydrogel scaffold (Gesim 2017)
a Fourth generation 3D Bioplotter manufacturer series b
with a schematic of the building platform (EnvisionTEC
2017)
a Technician assembling a prototype airway trainer. b
Patient’s missing orbital floor (left) versus original shape Realistic anatomic presentations models of
before impact (right) and the customized mould for the a hand and the b head illustrating all
titanium sheet pressing. c existing
Corrective osteotomy (realignment of bone from tissues (Stratasys Polyjet 2017)
deformity) to complex bone fractures. d Custom
orthopaedic exoskeleton
The use of additive manufacturing to improve healthcare solutions
