PDPM IIITDM Jabalpur October 5, 2024

Rapid Product Development Technologies RP/AM Processes

Since the presentation of first commercial application in 1987, a
Solid Based RP/AM Techniques large number of processes have been developed. Now a days commonly
used RP processes includes:-
Liquid Based
Stereolithography (SLA)
Digital Light Printing (DLP)
Instructor: Dr. Prashant K. Jain Masked Stereolithography (mSLA)
Professor (ME Discipline) Solid Ground Curing (SGC)
PDPM Indian Institute of Information Technology, Solid based
Design and Manufacturing Jabalpur, Jabalpur, INDIA Laminated Object Manufacturing (LOM)
Resources: web.iiitdmj.ac.in/~pkjain/ Fused Deposition Modeling (FDM)
Email: pkjain@iiitdmj.ac.in, pkjain2006@gmail.com Powder based
http://www.iiitdmj.ac.in/Faculty/pkjain.html
Three-Dimensional Printing (3DP)
http://in.linkedin.com/in/pkjain2006
https://www.facebook.com/pkjain2006 Selective Laser Sintering (SLS)
Laser Engineered Net Shaping (LENS)
PDPM Selective Laser Melting (SLM)/(DMLS)
INDIAN INSTITUTE OF INFORMATION TECHNOLOGY,
DESIGN AND MANUFACTURING JABALPUR
(An Institute of National Importance (INI) established by MHRD, Govt. of INDIA) October 5, 2024 Dr. Prashant K. Jain (IIITDMJ) 3

Laminated Object Manufacturing (LOM) Laminated Object Manufacturing Process

 The sheet material is

stretched from the supply
roller to the take-up roller;
 The heated laminated roller
passes over the sheet
bonding it to the previous
layer;
 Laser cuts the profile of that
layer and hatching the
excess material for later
removal;

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DeCubbing Ultrasonic Consolidation ( Fabrasonic)

 The de-cubing
process is to
assign shape of
waste material
into generally
small square
shape that can be
easily remove in
order to reduce
time and avoid
prototype
damages

Source : Fabrasonic
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PDPM IIITDM Jabalpur October 5, 2024

LOM ( Manufacturer: Impossible Objects) LOM Materials

 Papers
 Polymers
 Carbon Fibre, Fiberglass, Aramid Fibre (Kevlar), PBO(Zylon)
 Steel, Aluminium, Titanium
 Alumina, Zirconia, Zirconia-toughened alumina (ZTA), Silica
 Long fibre fabrics bonded with thermoplastic matrix materials
 Carbon fibre combined with either Nylon12
 PEEK and Glass fibre with Nylon 12

Source : Impossible Objects

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LOM: Advantages/Disadvantages LOM: Process parameters

• Advantages • Material
• Wide variety of materials • Thermal Conductivity
• Fast build time • Density
• High Precision • Heat Capacity
• No support structure • Part dimensions
• No post Curing • Layer thickness
• Ease of material handling • Number of Layers
• Multi-material layers possible (UAM) • Heat transfer Coefficient
• Air temperature
• Disadvantages
• Base plate Temperature
• Precise power adjustment
• Initial temperature of material
• Fabrication of thin wall difficult
• Roller velocity
• Layer height cannot be changed without changing the sheet thickness
• Roller contact strip width
• Difficult to remove the excess material after the laminating phase
• Roller temperature
• Integrity of prototypes • Heat transfer coefficient (roller to part)
• Removal of support

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Cubic Technologies- SD300

LOM: Manufacturers
Build material - Engineered
plastic
• Cubic Technologies Material color – amber
• http://www.cubictechnologies.com/ transparent
• FABRISONIC
Maximum model size – 160 W,
• https://fabrisonic.com/
210 L, 135 H
• Impossible Object
• https://impossible-objects.com/ Accuracy – 0.2 mm (x,y); 0.3
mm (z)
Input file formats – STL
Minimum wall thickness –1 mm

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PDPM IIITDM Jabalpur October 5, 2024

Fabrisonic’s SonicLayer 7200 Impossible Objects CBAM 25

Work Envelope - 72×72×36 inch. Work Envelope : 457

Material color – amber × 449 × 101 mm
transparent
Maximum model size
Maximum model size – 6×6×3
inch
: 18×17.7×4 inches
Accuracy Layer thickness : 50-
 Positioning : ± 0.0002 in. 60 micron
 Repeatability : ± 0.0001 in.
Print Accuracy : 125
microns

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LOM: Sample parts LOM Applications

Heat Exchangers Fusion of Dissimilar Metals

PCB solder pallets

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Fused Deposition Modeling (FDM) FDM: Process Details

Solid based
Support structures required
Capable to handle wide Model & Support Filaments
variety of material

Heated extrusion
head
Part

Elevator & Platform

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PDPM IIITDM Jabalpur October 5, 2024

FDM: Process Details FDM: Advantages/Disadvantages

• Advantages
• Parts can be made from a variety of materials
• Machine can be easily set up and used in an office environment
• Functional Prototypes can be built
• Negligible wastage
• Easy support removal
• Easy material change
• Simple Operations and Maintenance
• Disadvantages
• Support structures are needed;
• Parts have poor strength in the vertical direction;
• Process is slow on parts with large mass;
• Poor surface finish makes tooling routes unattractive.
• Limited accuracy
• Shrinkages and distortions
Source : SOLID CONCEPTS • Unpredictable shrinkage:
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FDM: Process Parameters

Materials
Operation Machine Material specific Geometry
specific specific specific ABS (Acrylonitrile Butadiene
Slice thickness Nozzle diameter Powder Fill vector Styrene)
characteristics length PLA (Polylactic Acid)

Road width Filament feed Binder Support Nylon (Aliphatic Polyamides)

rate characteristics structure HIPS (High-Impact
Head speed Roller speed Viscosity Polystyrene)
TPU (Thermoplastic
Extrusion Flow rate Stiffness
Polyurethane)
temperature
PEEK (Polyether Ether Ketone)
Envelope Filament Thermal
PEI (Polyetherimide)
temperature diameter conductivity
Carbon Fiber Reinforced
Fill pattern Filaments
Ceramic Filaments
Metal-Infused Filaments
Wood-Infused Filaments

October 5, 2024 Dr. Prashant K. Jain (IIITDMJ) 28 October 5, 2024 Dr. Prashant K. Jain (IIITDMJ) 29

FDM: Manufacturers Stratasys- Fortus 400mc

• Stratasys Build Volume- 355 x 254 x 254 mm

• http://www.stratasys.com/ (14 x 10 x 10 in.)
• RepRap Layer thicknesses: 0.330 mm (0.013
• http://reprapltd.com/ in.), 0.254 mm (0.010 in.), 0.178 mm
• FLASHFORGE (0.007 in.), 0.127 mm (0.005 in

• https://flashforge.com Achievable accuracy: Parts are

produced within an accuracy of ±
• Makerbot
.127 mm (± .005 in.) or ± .0015
• https://www.makerbot.com/
mm/mm (± .0015 in/in), whichever
• Aha3D is greater
• http://www.aha3d.in/

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PDPM IIITDM Jabalpur October 5, 2024

RepRap- Darwin FLASHFORGE CREATOR PRO 2

RepRap is humanity's first

general-purpose self- Build volume: 200*148*150 mm
replicating manufacturing Extruder Quantity : 2
machine.
Nozzle Diameter : 0.4 mm
Working volume: 230mm (X) Maximum Extruder Temperature
x 230mm (Y) x 100mm (Z) : 240℃ (464℉)
Feature size: about 2mm Print Speed : 30-100mm/s
Positioning accuracy: 0.1 mm Filament Diameter : 1.75mm
Layer thickness: adjustable, (0.069IN)
but nominally 0.3mm Layer Thickness : 0.1mm-0.4mm
Print Precision : ±0.2mm

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FDM: Sample parts

FDM: Sample parts Parts made on FDM 400mc at IIITDM Jabalpur

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Applications of RP Applications of RP

Functional model

BAE Systems using high-performance 3D printing thermoplastics,

3D printed Typhoon fighter including durable ABS and ASA materials for aircraft ground
aircraft cockpit floor equipment on the Typhoon fighter aircraft

Askja’s luxurious Origin hybrid amplifier

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PDPM IIITDM Jabalpur October 5, 2024

Applications of RP Applications of RP

Flexible Printing

Helmet prototype was 3D printed in one build

on the Stratasys F370

Assembly Printing
Assembly-line tool designed to hold switches
during laser marking operations. 3D printed in
3D Photo Printing
ASA material

October 5, 2024 Dr. Prashant K. Jain (IIITDMJ) 38 October 5, 2024 Dr. Prashant K. Jain (IIITDMJ) 39

Applications of RP Applications of RP

Multi-Color Printing Character Printing Rapid Casting Die

Artifacts Printing Fuze Percussion B-429 Fuze Percussion DA no 117

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Applications of RP Pellet Extrusion Printer

This technique involves using raw
plastic pellets instead of filaments.
In Pellet Extrusion, the pellets are
melted and extruded through a
nozzle to create the layers.

The most significant advantage of

Pellet extrusion technology is its
material availability.

Dental Cloning Fracture Diagnosis

Source: Pollen
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PDPM IIITDM Jabalpur October 5, 2024

Pellet Extrusion Working Principle Process Video

The extruder
consists of an auger
screw, extruder
die, heating
elements, and a
material cartridge
for the pellets.

Source: Pollen Source: Pollen

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Hybrid additive-subtractive manufacturing Cincinnati MAAM Printer

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Build strategies Formation of Sub-perimeter Voids

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PDPM IIITDM Jabalpur October 5, 2024

Raster Fill on a build layer Core Voids formation in Contour Fill

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Material flow synchronisation

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