The document discusses different types of manufacturing processes and additive manufacturing techniques. It describes forming, joining, removal, and additive manufacturing processes. It then focuses on additive manufacturing, explaining that it involves generating a 3D model and building the model layer-by-layer using different methods like stereolithography, fused deposition modeling, and selective laser sintering. The summary provides advantages and disadvantages of various additive manufacturing techniques for applications in industries like architecture, engineering and design.
The document discusses different types of manufacturing processes and additive manufacturing techniques. It describes forming, joining, removal, and additive manufacturing processes. It then focuses on additive manufacturing, explaining that it involves generating a 3D model and building the model layer-by-layer using different methods like stereolithography, fused deposition modeling, and selective laser sintering. The summary provides advantages and disadvantages of various additive manufacturing techniques for applications in industries like architecture, engineering and design.
The document discusses different types of manufacturing processes and additive manufacturing techniques. It describes forming, joining, removal, and additive manufacturing processes. It then focuses on additive manufacturing, explaining that it involves generating a 3D model and building the model layer-by-layer using different methods like stereolithography, fused deposition modeling, and selective laser sintering. The summary provides advantages and disadvantages of various additive manufacturing techniques for applications in industries like architecture, engineering and design.
The document discusses different types of manufacturing processes and additive manufacturing techniques. It describes forming, joining, removal, and additive manufacturing processes. It then focuses on additive manufacturing, explaining that it involves generating a 3D model and building the model layer-by-layer using different methods like stereolithography, fused deposition modeling, and selective laser sintering. The summary provides advantages and disadvantages of various additive manufacturing techniques for applications in industries like architecture, engineering and design.
The really old way: Take a block of material and carve it out
The more modern way:
Generate 3D model Generate CNC program Machine away unwanted material If possible, recycle waste
* Generate a 3D model * Software slices the 3D model into thin slices
* Machine builds it layer by layer
Advantages: Process is Independent of Part Feature No Blanks are Requires Tool less process Easily Automation Possible
*Video
1)STEREOLITHOGRAPHY Thin layers of UV sensitive liquid polymers are solidified through the use of a laser.
Stereo lithography is a photo polymerisation process.
Three main photopolymer systems used are acrylate , epoxy and vinyl ether.
Layer thickness-Each layer is 0.076 mm to 0.50 mm (0.003 in
to 0.020 in.) thick Scanning time is 500-25000 mm/s.
Part Built Time
Time to complete a single layer-
Ai Ti Td vD where Ti = time to complete layer i; Ai = area of layer i; v = average scanning speed of the laser beam at the surface; D = diameter of the spot size, assumed circular; and Td = delay time between layers to reposition the worktable
Total Time Once the Ti values have been determined for all layers, then the build cycle time is:
where Tc = STL build cycle time; and nl = number of layers
used to approximate the part Time to build a part ranges from one hour for small parts of simple geometry up to several dozen hours for complex parts
Benefits and downsides
Benefits No milling or masking steps needed.
Can be highly accurate
Only one material needed for build and support
Downsides Requires post curing of material
Long term curing can lead to warping
Can have brittle parts with a tacky surface
Support structures are often needed
Material is toxic and light sensitive
Heated thermoplastics are extruded through nozzles ,
extruded material hardens as it cools.
Benefits Can use standard engineering thermoplastics (ABS)
Can use multiple materials (One for bulid & support)
Can produce water tight parts
Parts are hardened very quickly
Downsides Poor layer uniformity
Delamination of extruded layers can be problematic
Parts can have a rather coarse surface finish
Molten/liquid plastics printed along with wax support
structure.
Lasers used to selectively sinter/fuse layers of powdered
materials.
SLA- Excellent surface finish suitable for presentation,
master models and light functional testing. FDM- Good combination of strength and surface finish at affordable price and lead time. 3DP- Suitable for general purpose parts for initial design stage with a quick delivery SLS- Range of materials available, soft like rubber to strong like metal. SLS Nylon suitable for snap and living hinge features
Architecture and Design
There is a quote in AM-
IF U CAN DRAW IT WE CAN PRINT IT
We are pushing our limits . Manufacturing is not the barrier to the entry , actually the design is the barrier to the entry.
THATS THE POWER OF TECHNOLOGY
And it marks the beginning of next industrial revolution.
Jane Chu, Sarah Engelbrecht, Gregory Graf, David W. Rosen, (2010) "A comparison of synthesis methods for cellular structures with application to additive manufacturing", Rapid Prototyping Journal, Vol. 16 Iss: 4, pp.275 283 Francis J. Quail, Thomas Scanlon and Matthew Strickland(2010) Development of a regenerative pump impeller using rapid manufacturing techniques ,Rapid Prototyping Journal Volume 16 Number 5 2010 pp 337344 Tomaz Brajlih, Bogdan Valentan, Joze Balic, Igor Drstvensek, (2011) "Speed and accuracy evaluation of additive manufacturing machines", Rapid Prototyping Journal, Vol. 17 Iss: 1, pp.64 75 wohlersassociates.com/terms.html additivemanufacturing.com/ www.ge.com/stories/additive-manufacturing www.docstoc.com/docs/71023917/ADDITIVE-MANUFACTURING-AND-THEENVIRONMENT www.arptech.com.au/slshelp.htm
