The document provides an introduction and overview of additive manufacturing (AM), including its classification into different systems based on the state of the building material (liquid, solid, powder). It describes important AM technologies like stereolithography (SLA), fused deposition modeling (FDM), and selective laser sintering (SLS). The document also includes an introduction to reverse engineering, covering its motivation and processes of extracting design information from manufactured products.
The document provides an introduction and overview of additive manufacturing (AM), including its classification into different systems based on the state of the building material (liquid, solid, powder). It describes important AM technologies like stereolithography (SLA), fused deposition modeling (FDM), and selective laser sintering (SLS). The document also includes an introduction to reverse engineering, covering its motivation and processes of extracting design information from manufactured products.
The document provides an introduction and overview of additive manufacturing (AM), including its classification into different systems based on the state of the building material (liquid, solid, powder). It describes important AM technologies like stereolithography (SLA), fused deposition modeling (FDM), and selective laser sintering (SLS). The document also includes an introduction to reverse engineering, covering its motivation and processes of extracting design information from manufactured products.
The document provides an introduction and overview of additive manufacturing (AM), including its classification into different systems based on the state of the building material (liquid, solid, powder). It describes important AM technologies like stereolithography (SLA), fused deposition modeling (FDM), and selective laser sintering (SLS). The document also includes an introduction to reverse engineering, covering its motivation and processes of extracting design information from manufactured products.
I 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. I The term AM encompasses many technologies including subsets like 3D Printing, Rapid Prototyping (RP), Direct Digital Manufacturing (DDM), layered manufacturing and additive fabrication. I AM application is limitless. Early use of AM in the form of Rapid Prototyping focused on preproduction visualization models. More recently, AM is being used to fabricate end-use products in aircraft, dental restorations, medical implants, automobiles, and even fashion products. Additive Manufacturing contd. Some Examples Some Examples contd. Some Examples contd. Some Examples contd. Additive vs Subtractive Manufacturing Additive vs Subtractive Manufacturing contd. Evolution of AM Technologies Evolution of AM Technologies contd. Current and Potential industries for Additive Manufacturing AM Benefits: Weight Reduction AM Benefits: Complexity for Free AM Benefits: Customized Medical Products Future: Home Manufacturing Generic AM Process Generic AM Process contd. Data path for additive manufacturing Classification of Additive Manufacturing Systems Liquid Based Additive Manufacturing Systems
I Building material is in the liquid state.
I The following AM Systems fall into this category: 1) Stereolithography Apparatus(SLA) 2) PolyJet 3D printing 3) Multijet Printing(MJP) 4) Solid Object Ultravoilet-Laser Printer(SOUP) 5) Rapid Freeze Prototyping I 1) and 4) are widely used method. Solid Based Additive Manufacturing Systems
I Building material is in the Solid state (except powder).
I The solid form can include the shape in the forms of wire, rolls, laminates and pellets. I The following AM Systems fall into this category: 1) Fused deposition modeling (FDM) 2) Selective Deposition Lamination (SDL) 3) Laminated Object Manufacturing (LOM) 4) Ultrasonic Consolidation Powder Based Additive Manufacturing Systems
I Building material is Powder(grain like form).
I All Powder Based AM Systems employ the joining/binding method. I The following AM Systems fall into this category: 1) Selective Laser Sintering(SLS) 2) ColorJet Printing(CJP) 3) Laser Engineered Net Shaping (LENS) 4) Electron Beam Melting(EBM) etc. Important Technologies of AM
I In the next few slides, we are going to discuss these three AM
I One of the most important additive manufacturing
technologies currently available. I The first ever commercial RP systems were resin-based systems commonly called stereolithography or SLA. I The resin is a liquid photosensitive polymer that cures or hardens Stereolithography when exposed to ultraviolet radiation. I This technique involves the curing or solidification of a liquid photosensitive polymer through the use of the irradiation light source. I The source supplies the energy that is needed to induce a chemical reaction (curing reaction), bonding large no of small molecules and forming a highly cross-linked polymer Stereolithography contd. Stereolithography contd. Stereolithography contd.
I Facts About SLA
1) Each layer is 0.076 mm to 0.50 mm thick 2) Starting materials are liquid monomers 3) Polymerization occurs on exposure to UV light produced by laser scanning beam - Scanning speeds - 500 to 2500 mm/s I Part Build Time in SLA Time to complete a single layer :
Ai Ti = + Td (1) 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 Stereolithography contd.
I Time to build a part ranges from one hour for small parts of simple geometry up to several dozen hours for complex parts I SLA Build Cycle Time : nl X Tc = Ti (2) i=1
where Tc = STL build cycle time; and nl = number of layers
used to approximate the part SLA 3D Printing Product Fused deposition modeling
I Fused Deposition Modeling (FDM), produced and developed
by Stratasys, USA. I FDM uses a heating chamber to liquefy polymer that is fed into the system as a filament. I The filament is pushed into the chamber by a tractor wheel arrangement and it is this pushing that generates the extrusion pressure. I The major strength of FDM is in the range of materials and the effective mechanical properties of resulting parts made using this technology. I Parts made using FDM are amongst the strongest for any polymerbased additive manufacturing process. Fused deposition modeling contd. Materials for FDM
I The most popular material is the ABSplus material, which can
be used on all current Stratasys FDM machines. I Some machines also have an option for ABS blended with Polycarbonate. Materials for FDM contd.
I Note that FDM works best with polymers that are amorphous in nature rather than the highly crystalline polymers. I This is because the polymers that work best are those that are extruded in a viscous paste rather than in a lower viscosity form. I As in amorphous polymers, there is no distinct melting point and the material increasingly softens and viscosity lowers with increasing temperature. I The viscosity at which these amorphous polymers can be extruded under pressure is high enough that their shape will be largely maintained after extrusion, maintaining the extrusion shape and enabling them to solidify quickly and easily. Limitations of FDM
I Sharp features or corners not possible to get;
I Part strength is weak perpendicular to build axis; I More area in slices requires longer build times; I Temperature fluctuations during production could lead to delamination FDM 3D Printing Product Selective Laser Sintering Selective Laser Sintering contd.
I Layer thickness: nearly 0.1 mm thick;
I The part building takes place inside an enclosed chamber filled with nitrogen gas to minimize oxidation and degradation of the powdered material; I The powder in the building platform is maintained at an elevated temperature just below the melting point and/or glass transition temperature of the powdered material; I Infrared heaters are used to maintain an elevated temperature around the part being formed; I A focused CO2 laser beam is moved on the bed in such a way that it thermally fuses the material to form the slice cross-section; I Surrounding powders remain loose and serve as support for subsequent layers. Advantages vs. disadvantages of SLS
I Advantages 1) A distinct advantage of the SLS process is that because it is fully self-supporting 2) Parts possess high strength and stiffness 3) Good chemical resistance 4) Various finishing possibilities (e.g., metallization, stove enameling, vibratory grinding, tub coloring, bonding, powder, coating, flocking) 5) Complex parts with interior components, channels, can be built without trapping the material inside. 6) Fastest additive manufacturing process I Disadvantages SLS printed parts have surface porosity. Such porosity can be sealed by applying sealant such as cyanoacrylate. SLS 3D Printing Product Introduction to Reverse Engineering
I It is the processes of extracting knowledge or design
information from anything man-made and reproducing it or reproducing anything based on the extracted information. I The process often involves disassembling something (a mechanical device, electronic component, computer program, or biological, chemical, or organic matter) and analyzing its components and workings in detail. I Product of World War II. Motivation for Reverse Engineering
I Interfacing: Reverse engineering can be used when a system
is required to interface to another system. I Military or commercial espionage: Learning about an enemy’s or competitor’s latest research by stealing or capturing a prototype and dismantling it. I Product security analysis: To examine how a product works, what are specifications of its components, estimate costs and identify potential patent infringement. I Academic/learning purposes: Reverse engineering for learning purposes may be to understand the key issues of an unsuccessful design and subsequently improve the design. I Saving money: when one finds out what a piece of electronics is capable of, it can spare a user from purchase of a separate product. Reverse Engineering Process I Prediction What is the purpose of this product? How does it work? I Observation How do you think it works? How does it meet design objectives (overall)? I Disassemble How does it work? How is it made? How many parts and moving parts? I Analyze Carefully examine and analyze subsystems (i.e. structural, mechanical, and electrical) and develop annotated sketches that include measurements and notes on components, system design, safety, and controls. Reverse Engineering Process contd.
I Test Carefully reassemble the product. Operate the device and record observations about its performance in terms of functionality (operational and ergonomic) and projected durability. I Documentation Inferred design goals Inferred constraints Design (functionality, form (geometry), and materials) Schematic diagrams Lists (materials, components, critical components, flaws, successes, etc.) Identify any refinements that might enhance the products usefulness. Upgrades and changes Reverse Engineering Process contd. Example of Reverse Engineering ...........
