Additive Manufacturing Technologies

Description

156614_1_En_BookFrontmatter_Online 156614_1_En_1_Chapter_Online Chapter 1: Introduction and Basic Principles What is Additive Manufacturing? What Are AM Parts Used For? The Generic AM Process Step 1: CAD Step 2: Conversion to STL Step 3: Transfer to AM Machine and STL File Manipulation Step 4: Machine Setup Step 5: Build Step 6: Removal Step 7: Postprocessing Step 8: Application Why Use the Term Additive Manufacturing? Automated Fabrication (Autofab) Freeform Fabrication or Solid Freeform Fabrication Additive Manufacturing or Layer-based Manufacturing Stereolithography or 3D Printing Rapid Prototyping The Benefits of AM Distinction Between AM and CNC Machining Material Speed Complexity Accuracy Geometry Programming Other Related Technologies Reverse Engineering Technology Computer-Aided Engineering Haptic-Based CAD About This Book Exercises References 156614_1_En_2_Chapter_Online 2: Development of Additive Manufacturing Technology Introduction Computers Computer-Aided Design Technology Other Associated Technologies Lasers Printing Technologies Programmable Logic Controllers Materials Computer Numerically Controlled Machining The Use of Layers Classification of AM Processes Liquid Polymer Systems Discrete Particle Systems Molten Material Systems Solid Sheet Systems New AM Classification Schemes Metal Systems Hybrid Systems Milestones in AM Development AM Around the World The Future? Rapid Prototyping Develops into Direct Digital Manufacturing Exercises References 156614_1_En_3_Chapter_Online Chapter 3: Generalized Additive Manufacturing Process Chain Introduction The Eight Steps in Additive Manufacture Step 1: Conceptualization and CAD Step 2: Conversion to STL Step 3: Transfer to AM Machine and STL File Manipulation Step 4: Machine Setup Step 5: Build Step 6: Removal and Cleanup Step 7: Post-process Step 8: Application Variations from One AM Machine to Another Photopolymer-Based Systems Powder-Based Systems Molten Material Systems Solid Sheets Metal Systems The Use of Substrates Energy Density Weight Accuracy Speed Maintenance of Equipment Materials Handling Issues Design for AM Part Orientation Removal of Supports Hollowing Out Parts Inclusion of Undercuts and Other Manufacturing Constraining Features Interlocking Features Reduction of Part Count in an Assembly Identification Markings/Numbers Application Areas That Don´t Involve Conventional CAD Modeling Medical Modeling Reverse Engineering Data Architectural Modeling Further Discussion Exercises References 156614_1_En_4_Chapter_Online Chapter 4: Photopolymerization Processes Introduction Photopolymerization Materials UV Curable Photopolymers Overview of Photopolymer Chemistry Resin Formulations and Reaction Mechanisms Photoinitiator System Monomer Formulations Interpenetrating Polymer Network Formation Reaction Rates Vector Scan SL SL Process Overview SL Machines SL Resin Curing Process Irradiance and Exposure Laser-Resin Interaction Photospeed Time Scales SL Scan Patterns Layer-Based Build Phenomena and Errors WEAVE STAR-WEAVE ACES Scan Pattern Vector Scan Microstereolithography Mask Projection Photopolymerization Technologies and Processes Mask Projection SL Technology Commercial MPSL Systems MPSL Modeling Two-Photon SL Summary Exercises References 156614_1_En_5_Chapter_Online Chapter 5: Powder Bed Fusion Processes Introduction SLS Process Description Powder Fusion Mechanisms Solid-state Sintering Chemically-induced Sintering Liquid-phase Sintering and Partial Melting Distinct Binder and Structural Materials Separate Particles Composite Particles Coated Particles Indistinct Binder and Structural Materials Full Melting Powder Handling Powder Handling Challenges Powder Handling Systems Powder Recycling Approaches to Metal and Ceramic Part Creation Metal Parts Ceramic Parts Variants of Powder Bed Fusion Processes Laser-based Systems for Low-temperature Processing Laser-based Systems for Metals and Ceramics Electron Beam Melting Line-wise and Layer-wise PBF Processes Process Parameters Applied Energy Correlations and Scan Patterns Typical Materials and Applications Materials Capabilities and Limitations Conclusions Exercises References 156614_1_En_6_Chapter_Online Chapter 6: Extrusion-Based Systems Introduction Basic Principles Material Loading Liquification Extrusion Solidification Positional Control Bonding Support Generation Plotting and Path Control Fused Deposition Modeling from Stratasys FDM Machine Types Materials Limitations of FDM Bioextrusion Gel Formation Melt Extrusion Scaffold Architectures Other Systems Contour Crafting Nonplanar Systems FDM of Ceramics Reprap and Fab@home Exercises References 156614_1_En_7_Chapter_Online Chapter 7: Printing Processes Evolution of Printing as an Additive Manufacturing Process Historical Development of 3D Printing Commercially Available Printing Machines Advantages of Printing Research Achievements in Printing Deposition Polymers Ceramics Metals Technical Challenges of Printing Droplet Formation Technologies Continuous Mode Drop-on-Demand Mode Other Droplet Formation Methods Printing Process Modeling Material Modification Methods Hot Melt Deposition Solution- and Dispersion-Based Deposition Prepolymer Deposition Three-Dimensional Printing Technology Commercial Machines Other Materials Advantages of Binder Printing Exercises References 156614_1_En_8_Chapter_Online Chapter 8: Sheet Lamination Processes Gluing or Adhesive Bonding Bond-then-Form Processes Form-then-Bond Processes Thermal Bonding Processes Based on Sheet Metal Clamping Ultrasonic Consolidation UC Bond Quality UC Process Fundamentals UC Process Parameters and Process Optimization Oscillation Amplitude Normal Force Sonotrode Travel Speed Preheat Temperature Microstructures and Mechanical Properties of UC Parts Defects UC Microstructures Mechanical Properties Modeling of UC UC Applications Internal Features Material Flexibility Fiber Embedment Smart Structures Conclusions Exercises References 156614_1_En_9_Chapter_Online Chapter 9: Beam Deposition Processes Introduction General Beam Deposition Process Description Material Delivery Powder Feeding Wire Feeding BD Systems Process Parameters Typical Materials and Microstructure Processing-Structure-Properties Relationships BD Benefits and Drawbacks Exercises References 156614_1_En_10_Chapter_OlLine Chapter 10: Direct Write Technologies Direct Write Technologies Background Ink-Based DW Nozzle Dispensing Processes Quill-Type Processes Inkjet Printing Processes Aerosol DW Laser Transfer DW Thermal Spray DW Beam Deposition DW Laser CVD Focused Ion Beam CVD Electron Beam CVD Liquid-Phase Direct Deposition Beam Tracing Approaches to Additive/Subtractive DW Electron Beam Tracing Focused Ion Beam Tracing Laser Beam Tracing Hybrid Technologies Applications of Direct Write Technologies Exercises References 156614_1_En_11_Chapter_Online Chapter 11: Design for Additive Manufacturing Motivation Design for Manufacturing and Assembly Core DFAM Concepts and Objectives Complex Geometry Customized Geometry Integrated Assemblies Elimination of Conventional DFM Constraints AM Unique Capabilities Shape Complexity Hierarchical Complexity Functional Complexity Material Complexity Exploring Design Freedoms Part Consolidation and Redesign Hierarchical Structures Industrial Design Applications Design Tools for AM Challenges for CAD Solid-Modeling CAD Systems Promising Technologies Proposed DFAM System Implicit Modeling Search and Synthesis Methods Cantilever Beam Example Summary Exercises References 156614_1_En_12_Chapter_Online Chapter 12: Guidelines for Process Selection Introduction Selection Methods for a Part Decision Theory Approaches to Determining Feasibility Approaches to Selection Selection Example Challenges of Selection Example System for Preliminary Selection Production Planning and Control Production Planning Pre-processing Part Build Post-processing Summary Open Problems Exercises References 156614_1_En_13_Chapter_Online Chapter 13: Software Issues for Additive Manufacturing Introduction Preparation of CAD Models - the STL File STL File Format, Binary/ASCII Creating STL Files from a CAD System Calculation of Each Slice Profile Technology Specific Elements Problems with STL Files STL File Manipulation Viewers STL Manipulation on the AM Machine Beyond the STL File Direct Slicing of the CAD Model Color Models Multiple Materials Use of STL for Machining Additional Software to Assist AM Exercises References 156614_1_En_14_Chapter_Online Chapter 14: Direct Digital Manufacturing Align Technology Siemens and Phonak Custom Soccer Shoes and Other DDM Examples DDM Drivers Manufacturing vs. Prototyping Cost Estimation Cost Model Build Time Model Stereolithography Example Life-Cycle Costing Future of Direct Digital Manufacturing Exercises References 156614_1_En_15_Chapter_Online Chapter 15: Medical Applications for Additive Manufacture Introduction The Use of AM to Support Medical Applications Surgical and Diagnostic Aids Prosthetics Development Manufacturing Tissue Engineering and Organ Printing Software Support for Medical Applications Limitations of AM for Medical Applications Speed Cost Accuracy Materials Ease of Use Further Development of Medical AM Applications Approvals Insurance Engineering Training Location of the Technology Service Bureaus Exercises References 156614_1_En_16_Chapter_Online Chapter 16: Post-Processing Support Material Removal Natural Support Post-Processing Synthetic Support Removal Supports Made from the Build Material Supports Made from Secondary Materials Surface Texture Improvements Accuracy Improvements Error Sources Model Pre-processing Machining Strategy Adaptive Raster Milling Sharp Edge Contour Machining Hole Drilling Aesthetic Improvements Preparation for use as a Pattern Investment Casting Patterns Sand Casting Patterns Other Pattern Replication Methods Property Enhancements using Non-thermal Techniques Property Enhancements using Thermal Techniques Conclusions Exercises References 156614_1_En_17_Chapter_Online Chapter 17: The Use of Multiple Materials in Additive Manufacturing Introduction Multiple Material Approaches Discrete Multiple Material Processes Porous Multiple Material Processes Blended Multiple Material Processes Embedded Component AM Commercial Applications Using Multiple Materials Future Directions Design Tools Analysis Multi-axis Systems Materials Development Applications Conclusions Exercises References 156614_1_En_18_Chapter_Online Chapter 18: Business Opportunities and Future Directions Introduction New Types of Products and Employment New Types of Products New Types of Employment Digiproneurship Conclusions Exercises References 156614_1_En_BookBackmatter_Online