The Additive Manufacturing Processes - Report Example

THE ADDITIVE MANUFACTURING PROCESSES Name University Course Date Table of Content Introduction…………………………………………………………….………3 The experiential Report of the laboratory session...............................................5 Stereolithography (SL)…………………………………………………………6 Fused Deposition Modelling (FDM)............................................................…...8 The Selective Laser Melting (SLM)……………………………………….….12 The Laser Deposition Technology (LDT)………………………………….…13 The Role of Additive Manufacturing in Automotive Engineering……………16 Future View about 3D Printing..................................................................…...19 Conclusion…………………….……………………………………………….20 Bibliography….………………………………………………………………..21 Introduction Additive manufacturing (AM) primarily refers to the process by which the digital 3D design data is employed to develop a component in layers by simply depositing material. The article is a report on the laboratory session whose main aim is to provide the student with a first-hand laboratory demonstration in various AM technologies. As it will be seen, the process compromises a lot of advantages in the development of parts, presentations of supreme design choice with the capability to manufacture both single and multiple types of machinery from an extensive scope of materials. Other terminologies like 3D Printing, Freeform Fabrication, Additive Fabrication, Additive Layer Manufacturing and Fibbing are also used to refer to the process (Kianian, Tavassoli and Larsson, 2015). Figure 1 below is an example of the end products of the AM Figure 1 The first AM processes were discovered in the mid-1980s as an answer to quick product development. The processes commercialised in 1887 to Stereolithography (SL) that offered new designers and engineers new possibilities to support short life products. New polymer related AM technologies started to commercialise in the 1990s. They included the fused deposition (FDM) from the Stratasys, laminated manufacturing (LOM) that came from Helisys, Solid Ground Curing (SGC) from the Cubital and the selective laser sintering (SLS) from the DTM (Corcione, 2014). The processes have gradually evolved since then. The technologies are now applied in a diverse range of industries from the consumer electronics, automotive, and consumables sectors. Besides, they are also employed by individual consumers and for medical application. The techniques are focused on in try to develop better products due to the benefits it offers when compared to the traditional methods (Kianian, Tavassoli and Larsson, 2015). Finally, the on-going progress of the AM system has assisted the fabrication of parts created in the anticipated material in a single-step process. It is now probable to develop virtually 100% dense, efficient designs (Yasa, Kruth and Deckers, 2011). Over time, these techniques have become more effective and reliable with the scope of the appropriate materials rising significantly. Image 1 The experiential Report of the laboratory session There are variates of individual processes with varying methods of layer manufacturing that are involved in the additive manufacturing (Singh, 2014). The procedures vary based on the material and the technology applied. The object to be created is first by making a virtual design of the object that needs to be created. The virtual design is created in a computer aided design (CAD) file by the use of a 3D scanner (for copying of the existing objects) or by a 3D modelling program (incase of creating totally new object). The 3D scanner creates a 3D digital copy of the existing object by application of different technologies. For example, the time-of-flight, modulating/structured ligh,and volumetric scanning among others. After that, the object is then printed layer by layer by the printers. Below is the graph showing the printing progress of the AM Graph 1 Below are some of the techniques formulated by the “American Society for Testing and Materials (ASTM)” as the “Standard Terminology for Additive Manufacturing Technology, 2012”. Stereolithography (SL) Unlike the desktop printer, SLA machine begins with an additional of melted plastic, some of which are hardened or cured to form a solid object. The machine have four sections: a perforated platform, which is lowered in the tank, a tank that is filled with fluid plastic (photopolymer), an ultraviolet (UV) laser and finally a computer that is used to regulate the laser and the platform (Corcione, 2014). Figure 2 showing part of the Stereolithography process In the first step of the process, a tiny layer of the photopolymer is exposed on the perforated platform. The UV laser is used to hit the perforated platform thus painting the shape of the item being printed (see graph 2 for the printing progress). The UV-curable fluid hardens immediately the UV laser touches it, hence creating the first coat of the 3D- printed item (Corcione, 2014). Graph 2 The platform is then sunk, exposing a new superficial layer of the molten polymer. The laser then gains dashes across a segment of the item being printed that immediately bonds to the toughened section beneath it. The procedure is repeated until the whole object has been created and is completely immersed in the tank. The platform is finally raised to expose the 3D object. After the object is cleaned with a molten solvent to free it of extra resin, it is then scorched in a UV oven to supplementary cure the plastic. The figures below shows some of the objects created through the SL process Figure 3 The objects that are created through stereolithography normally have a smooth surface (see figure 4), though the quality rest on the excellence of the SLA machine that is used to print it. The size of the SLA machine used determines the time the object takes to be created (Corcione, 2014). Small machines are used to create small objects and normally take between six to twelve hours to print an object. Big objects that are several metres can take some days. Figure 4 Fused Deposition Modelling (FDM) Objects developed with the FDM printer begins out as computer-aided design (CAD) files. The object CAD file must be changed to a format, which a 3D printer understands the object, can be printed (Rahim and Maidin, 2014). The printer utilises two type of material. The modelling material that consisting of the finished object and the supporting material that acts as the scaffolding to back-up the object as it is printed (see graph 3). Figure 5 showing an example of FDM process Graph 3 showing the printing rate against time taken Throughout the printing, these materials typically take the form of the plastic threads, or the filaments that are relaxed from the coil and then fed through an extrusion nozzle as shown in figure 6. The nozzle dissolves the filament and then extrudes them onto a base. Both the base and the nozzle are controlled by the computer, which decodes the dimensions of the object into X,Y and the Z coordinates for the base and the nozzle to follow during the printing (Rahim and Maidin, 2014). Figure 6 In the FDM system, an extrusion nozzle transfers over the build platform vertically and horizontally, drawing the cross segment of the item onto the platform. The thin layer of the plastic cools and toughens instantly necessary to the layer underneath it. Immediately the layer is completed; the base is sunk: frequently, by around one-sixteenth of an inch. This is to create a room for the next layer of the plastic. Figure 7 showing examples of the objects created through the FDM The FDM printing time usually depends on the scope of the object that is being created. The FDM process is relatively slow compared to other methods like the selective laser sintering and stereolithography. Just like the stereolithography, smaller and thin objects usually prints first while more complex ones take longer time (Kianian, Tavassoli and Larsson, 2015). The supporting are then removed once the object comes out of the FDM printer by smoking of the object in water and a detergent solution or, by snapping the supporting material off by the hand for the case of thermoplastic supports. The objects may also be milled, sanded, planted or printed to improve their function and the appearance example the images shown in figure 8 and 9 (Rahim and Maidin, 2014). Figure 8 The technique can handle materials such as ABS- strong and tough plastic that are perfect suite to functional prototype, PLA- biodegradable polymer created from starch, BronzeFill- metal printing on the FDM machine, and the PET-Food safe, hard and dimensionally stable (Rahim and Maidin, 2014). Figure 9 The Selective Laser Melting (SLM) The process begins by the slicing of the 3D file data into layers, typically from 20 to 100 micrometres thick to make a 2D image of every layer(see figure 10). The file is then loaded into a file grounding software package, which assigns it values, parameters and physical support. This enables the file to be understood and created by the various kinds of the additive manufacturing machines (Yasa, Kruth and Deckers, 2011). Figure 10 The selectively dissolves thin layer of the atomized well metallic power is equally dispersed using a coating machine onto a substrate plate that is speeded to an indexing stand that moves on a vertical axis. The process proceeds to a chamber comprising a tightly precise environment of the inert gas, either nitrogen or argon at an oxygen level less than 500 parts per million (Yasa, Kruth and Deckers, 2011). Figure 11 showing an object created through the SLM Once every layer has been dispersed, every 2D slice of the part geometry is merged by selectively rendering the powder. This is usually a attained with a high-power laser beam, normally a ytterbium fibre laser having hundreds of watts. The laser beam is focussed in the Y and X directions with two high frequency-scanning mirrors. Usually, the laser beams powerful enough to allow the full melting of the particles to result in a solid metal. The process is the repeated a layer after a layer until the required part is complete (Singh, 2014). The selective laser melting is in its beginning with comparatively few users when compared to other additive manufacturing techniques (Yasa, Kruth and Deckers, 2011). Most of the machines work with a created chamber of 250 mm in the X and Y axis, and up to 350 mm in the Z axis. However, larger machines operate with up to 500 mm in both X,Y and Z axis. The kind of materials, which can be handled includes tool sheet, stainless steel, aluminium, titanium and the cobalt chrome (Yasa, Kruth and Deckers, 2011). Both of them must occur in an atomized form and display certain flow features in order to be process accomplished. The following images in figure 12 shows examples of the SLM products. Figure 12 The Laser Deposition Technology (LDT) With the laser deposition technology, the metal powder is introduced into a focused beam of a very high-power laser. The process takes place under strongly controlled atmospheric environments. The dedicated laser beam then melts the surface of the aimed materials and produces a small-liquefied pool of the base material (Koslovskiy, 2010). See figure 13 below. Figure 13 After that, the powder delivered into the same sport is then absorbed into the melt pool, therefore, generating a deposit that can range from 0.005 to 0.040in. thick and from 0.040 to 0.160 in. wide. Therefore, the resulting deposits can then be used to create or repair metal parts for a broad range of different applications (Koslovskiy, 2010). Below is figure that that shows some of the LDT machines. Figure 14 Generally, the term laser deposition technology is used like a blanket name that comprises of many processes like the direct metal deposition (DMD), laser metal deposition, laser additive manufacturing (LAM), and the many others that applies the use of focused laser beam as the heat source for the deposition of powered metals (Koslovskiy, 2010). Figure 15 showing some of the LDT products The Role of Additive Manufacturing in Automotive Engineering The outburst in the application of the additive manufacturing (AM) has created huge chances for the automotive industry. The market study from the IBIS World found that of about 86 million automobiles were developed globally in the year 2013 (Kianian, Tavassoli and Larsson, 2015). With such a competitive environment, it has become inevitable for the small players in the parts manufacturing sections to emphasis on the creation cost-effective and ability to succeed among their competitors. Therefore, manipulating on the possible of the AM for the fast prototyping is what keeps the future for the OEMs and the aftermarket traders to meet the rapid changing market necessities. Figure 16 showing some of the competitive products from the AM Although, parts like cooling vents, housings and the dashboards are previously being made using the AM mechanism by majority manufactures, its request is still limited mainly because of a slim choice of the material that can be applied. With such, what now lies ahead for the AM is the capability to create or the 3D print of the parts that are made up of various materials, which can be built rapidly. The Deloitte University conducted research to predict the future ability of the AM technology on advanced materials. This was mainly because of the wide advantages that the AM offers. The ability to include the innovation in the product manufacturing with a reduction in tooling cost and accelerated development process makes printing parts an important choice for the automotive field (Kianian, Tavassoli and Larsson, 2015). Several other researchers have already been carried out on the ascertaining compatibility of the advanced material with the 3D printing. These studies are necessary as the application of the materials nowadays for the 3D technique is a commonly proprietary polymer. There is also a probability to employee steel alloys and the titanium, although, because of an anisotropy triggered by the layer-by-layer method, the physical features are not as resilient as the conservatively manufactured ones. It has also been noticed that the application of the metallic nanoparticles in the sintering procedure gradually improves the parts density and reduces shrinkage and the distortion of the part printed. Therefore, the embedding of these nanoparticles into the polymer materials also can increase the electrical conductivity of the fabricated products. Besides, the combination of several differed nanomaterials for the development of the single part applying the AM technology would open the likelihood to print compound products such as batteries, fuel cells and solar cells (Kianian, Tavassoli and Larsson, 2015). With the application of nanotechnology, advancement in the strength without a conforming addition in the weight of the creation can be made possible. This will be a main motivational feature towards the manufacture embracing of the AM. Furthermore, the other conspicuous progressive material for the 3D printing is the carbon fiber. The material is increasingly being used by the vehicle manufacturers to develop car roofs, windshield frames and the fender. Carbon fiber being light in its weight gives a remarkable strength against thankfully and the deformation. Likewise, the additive manufacturing takes the advantage of this carbon. Graph 4 show the printing rate for various materials Graph 4 The modern launch of the commercial additive manufacturing trick by the MARKFORGG3D, is allegedly the initial carbon fiber 3D printer (see figure 17), therefore, it has open a whole innovative set of chances to construct carbon fiber parts for the automobiles. Figure 17 showing an example of a 3D printer Nevertheless, the main attractive material for the automotive manufacturer development is the Titanium; primarily, because of its important properties like the low density, resistance to corrosion and the high strength. Despite its so many pros, the viability of the Titanium for the additive manufacturing is restricted mainly by the costly methods to produce the metal powder. Therefore, to overcome its cost barrier, Metalysis untested a method to yield the Titanium powder in the one-step that lowers the charge by as much as 75 percent (Kianian, Tavassoli and Larsson, 2015). Following the research creativities circulating around the additive manufacturing and the advanced materials, there is a massive volume of chances to be unlocked by the automotive sector. Tier-1 and the Tier-2 supplies should be quick enough to grab the pros that the additive manufacturing technique gives and the concurrently convert their supply-chain into a leaner and a snugger environment. However, as much as the doors for the conservative construction is still open and will still play a dominant role in the automotive manufacturing, the additive manufacturing is making an inroad and it is obvious to change the global shape of the automotive industry (Kianian, Tavassoli and Larsson, 2015). Future View about 3D Printing Despite the current capability of the 3D printers, engineers anticipates changes ahead. They predicts the global market for the 3D printers and the services to grow by a large margin comes 2018. The industry aims at the printer that will enable the printing finished and more fully functional products or objects in large volumes that highly outnumbers the volume produced by the prototype. The technology targets to advance through the loosely coordinated development in the type of printers, the printing method, the material used and the software to design and print. Conclusion The process of AM has increased completion in the automotive industry. The process through its various technologies has facilitated the creation of best quality products in various sectors of manufacturing. The materials are laid down under the computer control and are produced from a 3D model like the 3D scanner. The AM process is based on layer by layer development of the objects. The terminology (AM) has now expanded to accommodate a broad range of techniques like the laser sintering and the extrusion based process. However the industry holds higher hopes for advancement in the near future especially in term of the equipment used. Bibliography Corcione, C. (2014). Development and characterization of novel photopolymerizable formulations for stereolithography. Journal of Polymer Engineering, 34(1). Kianian, B., Tavassoli, S. and Larsson, T. (2015). The Role of Additive Manufacturing Technology in Job Creation: An Exploratory Case Study of Suppliers of Additive Manufacturing in Sweden. Procedia CIRP, 26, pp.93-98. Koslovskiy, V. (2010). Progress in laser and electro-optics research. New York: Nova Science Publishers. Rahim, S. and Maidin, S. (2014). Feasibility Study of Additive Manufacturing Technology Implementation in Malaysian Automotive Industry Using Analytic Hierarchy Process. AMR, 903, pp.450-454. Singh, R. (2014). Advancement in manufacturing processes. Zurich: Trans Tech Publishers. Yasa, E., Kruth, J. and Deckers, J. (2011). Manufacturing by combining Selective Laser Melting and Selective Laser Erosion/laser re-melting. CIRP Annals - Manufacturing Technology, 60(1), pp.263-266. Read More

Figure 1 below is an example of the end products of the AM Figure 1 The first AM processes were discovered in the mid-1980s as an answer to quick product development. The processes commercialised in 1887 to Stereolithography (SL) that offered new designers and engineers new possibilities to support short life products. New polymer related AM technologies started to commercialise in the 1990s. They included the fused deposition (FDM) from the Stratasys, laminated manufacturing (LOM) that came from Helisys, Solid Ground Curing (SGC) from the Cubital and the selective laser sintering (SLS) from the DTM (Corcione, 2014).

The processes have gradually evolved since then. The technologies are now applied in a diverse range of industries from the consumer electronics, automotive, and consumables sectors. Besides, they are also employed by individual consumers and for medical application. The techniques are focused on in try to develop better products due to the benefits it offers when compared to the traditional methods (Kianian, Tavassoli and Larsson, 2015). Finally, the on-going progress of the AM system has assisted the fabrication of parts created in the anticipated material in a single-step process.

It is now probable to develop virtually 100% dense, efficient designs (Yasa, Kruth and Deckers, 2011). Over time, these techniques have become more effective and reliable with the scope of the appropriate materials rising significantly. Image 1 The experiential Report of the laboratory session There are variates of individual processes with varying methods of layer manufacturing that are involved in the additive manufacturing (Singh, 2014). The procedures vary based on the material and the technology applied.

The object to be created is first by making a virtual design of the object that needs to be created. The virtual design is created in a computer aided design (CAD) file by the use of a 3D scanner (for copying of the existing objects) or by a 3D modelling program (incase of creating totally new object). The 3D scanner creates a 3D digital copy of the existing object by application of different technologies. For example, the time-of-flight, modulating/structured ligh,and volumetric scanning among others.

After that, the object is then printed layer by layer by the printers. Below is the graph showing the printing progress of the AM Graph 1 Below are some of the techniques formulated by the “American Society for Testing and Materials (ASTM)” as the “Standard Terminology for Additive Manufacturing Technology, 2012”. Stereolithography (SL) Unlike the desktop printer, SLA machine begins with an additional of melted plastic, some of which are hardened or cured to form a solid object. The machine have four sections: a perforated platform, which is lowered in the tank, a tank that is filled with fluid plastic (photopolymer), an ultraviolet (UV) laser and finally a computer that is used to regulate the laser and the platform (Corcione, 2014).

Figure 2 showing part of the Stereolithography process In the first step of the process, a tiny layer of the photopolymer is exposed on the perforated platform. The UV laser is used to hit the perforated platform thus painting the shape of the item being printed (see graph 2 for the printing progress). The UV-curable fluid hardens immediately the UV laser touches it, hence creating the first coat of the 3D- printed item (Corcione, 2014). Graph 2 The platform is then sunk, exposing a new superficial layer of the molten polymer.

The laser then gains dashes across a segment of the item being printed that immediately bonds to the toughened section beneath it. The procedure is repeated until the whole object has been created and is completely immersed in the tank. The platform is finally raised to expose the 3D object. After the object is cleaned with a molten solvent to free it of extra resin, it is then scorched in a UV oven to supplementary cure the plastic. The figures below shows some of the objects created through the SL process Figure 3 The objects that are created through stereolithography normally have a smooth surface (see figure 4), though the quality rest on the excellence of the SLA machine that is used to print it.

Read More