Summary Additive Manufacturing Revision Poster

ME20026: ADDITIVE MANUFACTURING TECHNOLOGIES:
RAPID PROTOTYPING OR RAPID MANUFACTURING:
Stereolithography (SLA): Selective Laser Sintering (SLS) and Laminated Object Manufacturing:
COMPOSITES:
 Liquid polymer cured selectively into solid Electron Beam Melting: (EBM):  Layers of material (usually vinyl, plastic
 Uses computer controlled additive Spray Layup and Hand Layup (Contact Moulding):
to createdistinct
component  Non-metallic or metallic powder or paper) cut using computer controlled
 Composite
machines material is combination of two or more chemically and  Single mould is used
insoluble phases with a recognisable interface  Platform that can be lowered andoraised Thus isalso referred sintered
to as
or melted using laser (SLS)
open-mould processing machines
 Components often created layer by put in vat of polymer or electron beam (EBM) to achieve o Using lasers or cutters
 Their
layerproperties and structural performance are generally superior to those
 Platform is raised to highest position so desired shape  Material is stacked on top of each other
of constituents acting
 Sometimes known as layer basedindependently  Hand layup
only thin layer of polymer covers it  Thin layer of powder is deposited to form the object
 Dispersed phasemethods
manufacturing or fibres generally made of o Simplest method of contact moulding
o Position a in part build area o Stacking may be manual or
o Glass o Materials are placed in proper order
 Ultraviolet laser traces shape of  Beam scans shape of layer to automatic
o Carbon o Brushed
bottommost layer of component sinter powder particles into a solid  Cross-hatch pattern often cut into parts
o Boron o Shaped in mould by hand with a roller
o Cures polymer into solid  Build area is lowered that will be removed
 Fused Filament
Continuous Fabrication
phase or matrix(FFF):  Squeezing action of layer
rollerof
expels trapped air bubbles and compacts the part
 o Extruder head moves in two directions  Platform is lowered so thin layer of Fresh powder is deposited o Simplifies removal of excess
Thermosets
over a table polymer covers part on top for next layer to be built material
o Thermoplastics  Uses
 Process is repeated until reaching topmost
o oMetals
Table can be lowered or raised as
o SLS
required layer of part
o Ceramics Plastics
o Position c
 Reinforced
Filament,plastics
usually thermoplastic,
o EBM
extruded through small orifice or  Possible to fabricate layers that have larger
Spray layup
o Aka  Titanium andinto
cobalt-
heated die surface area on smaller layers o Moulding is done by spraying materials mould
 Polymer-matrix composites (PMC) chrome alloys over mould surfaces
 Complex geometries created one layer o Position b o Both resin and chopped fibres are sprayed
 Fibre-reinforced plastics (FRP)
 Generally weak support structureoinRolling shape deposited materials may be necessary in the process
o atHigh
a timespecific strength
o  Through controlled motion of of perforated structure is manufactured
Strength to weight ratio
extrusion o Holds overhanging parts of component
o High specific head in relation to table
stiffness
o  Through switching head on and off o Removed in post-processing
Stiffness to weight ratio
 o When one layer is
Good fatigue resistancecomplete, the table is
o lowered
Easy tofor the next
design, to be and
fabricate builtrepair
 Metal-matrix composites (MMC) Filament Winding:
o Higher toughness  Resin and fibres combined at time of curing
o Higher ductility o Develops composite structure
o Higher resistance to elevated temperatures  Parts produced onThree-Dimensional
rotating mandrel Printing
o Axisymmetric parts  Printing head deposits binder onto layer of polymer, ceramic or metal powder
o More difficult to manufacture
 Ceramic matrix composites (CMC) o Non-symmetric parts Build area is lowered
 Reinforcing filament tape, o orSimilar to SLS
roving, is wrapped continuously around the form
o Offer highest resistance to elevated temperatures and corrosive
 Reinforcements are impregnated
Another layer by of powder
passing themis deposited
through athen fusedbath
polymer by binder
environments
 Process can be modified  Process continues
by wrapping until all
mandrel layers
with have been
pre-preg manufactured
material
 Strong products produced  Process usingcan beprocess
this combined with sintering and metal infiltration
 Techniques for manufacturing PMCs
o Due to highly o Produces
reinforced structuredenser and stronger parts
o Fibre impregnation
 Includes o Can produce parts up to 4.5m diameter and 20m long
 Prepregs  Use
 Sheet-moulding compound o Strengthening cylindrical or spherical pressure vessels made of materials such as aluminium and
 Bulk-moulding compound titanium
 Thick-moulding compound  Presence of metal inner lining makes part impermeable
o Moulding of reinforced plastics
o Filament welding
o Pultrusion
o Pulforming
 Many composites require to be cured
o Subject to controlled high temperatures
o Achieves peak strength after forming