Mold and Die Making: Employing AM for rapid prototyping of molds and dies or for
creating conformal cooling channels.
Medical: Using AM techniques such as powder bed fusion or stereolithography to produce
patient-specific implants and surgical guides.
5. Post-Processing:
Automotive: Machining or finishing processes to achieve final dimensions and surface
quality.
Aerospace: Heat treatment and surface finishing for improved mechanical properties and
aerodynamics.
Foundry and Casting: Post-processing of casting patterns and cores for surface smoothness
and dimensional accuracy.
Mold and Die Making: CNC machining for precise finishing and fitting of components.
Medical: Sterilization and surface treatment to ensure biocompatibility and patient safety.
6. Quality Control:
Automotive: Non-destructive testing (NDT) methods like CT scanning or ultrasonic testing
for defect detection.
Aerospace: Stringent inspection using advanced techniques such as computed tomography
(CT) and coordinate measuring machines (CMM).
Foundry and Casting: Inspection of casting patterns and cores for dimensional accuracy and
surface defects.
Mold and Die Making: Precision measurement and inspection to ensure molds meet exacting
specifications.
Medical: Verification of implant dimensions and biocompatibility through imaging and
testing.
By following these steps tailored to each industry, additive manufacturing can be effectively applied
to produce high-quality components with complex geometries and optimized performance
characteristics.
UNIT – 5
SUPPORT MATERIAL REMOVAL is a crucial step in the post-processing of both polymer
and metal additive manufacturing (AM) parts.
For Polymer AM Parts:
1. Manual Removal: Support structures are manually removed using hand tools such as pliers,
tweezers, or cutters. Careful attention is paid to avoid damaging the part's surface.
2. Chemical Dissolution: Some polymers, such as ABS or PLA, can be dissolved in specific solvents.
Immersing the part in the solvent dissolves the support structures, leaving the printed part intact.
However, this method may require careful handling and disposal of the solvent.
3. Water Jetting: High-pressure water jets are used to remove support material from polymer parts.
The force of the water stream effectively dislodges the support structures without damaging the part's
surface.
4. Thermal Removal: Heat can be applied to soften the support material, making it easier to remove
manually or with minimal force. This method is suitable for thermoplastic polymers that soften at
elevated temperatures.
For Metal AM Parts:
1. Manual Removal: Similar to polymer parts, support structures for metal AM parts can be manually
removed using hand tools. However, metal supports may be more challenging to remove due to their
higher strength and hardness.
2. Machining: CNC machining or other subtractive manufacturing methods can be used to mill or
turn away support material from metal parts. This method offers precise control over the removal
process but may result in additional material waste.
3. Chemical Etching: Chemical etching processes can selectively dissolve support material from
metal parts while leaving the desired part unaffected. Acidic or alkaline solutions are commonly used
for this purpose.
4. Electrochemical Machining (ECM): ECM uses an electrolyte and a high-current electrical charge
to selectively dissolve material from metal parts, including support structures. It offers precise and
controlled material removal without mechanical force.
Considerations for Support Material Removal:
- Surface Finish: Care should be taken to avoid damaging the surface finish of the printed part during
support removal, especially for parts with critical surface features.
