Introduction to
Additive
Manufacturing
By: Asma Alhosani
Where Can We Find 3D Printing?
Automotive
Aerospace
Architecture
INTRODUCTION TO ADDITIVE
MANUFACTURING (AM)
Process of creating objects by adding material
layer by layer, based on a digital design
1. Versatility in creating complex geometries.
2. Reduced material waste compared to
conventional methods.
3. Rapid prototyping and production of custom
parts.
EARLY INNOVATIONS IN AM
Selective Laser Sintering Kodama developed MIT's 3D Printing
(SLS) in 1979 by Dr. Ross photopolymerization Invention (1995)
Housholder processes in 1980 Professors Sachs &
Cima
Subtractive (Top-Down) vs. Additive (Bottom-Up)
Traditional AM builds layer
Comparison with Conventional machining by layer, using
Manufacturing removes material only the material
from a block. needed.
-Complex geometries
-Minimal waste
-No tooling required
-Fast prototyping
Current Applications in AM
General Electric (GE):
3D printing jet engine
parts, improving fuel
efficiency. Nike: Personalized
athletic shoe soles.
Custom Implants:
Patient-specific
implants
AM Technologies
Fused filament fabrication: Stereolithography: Curing Powder Bed Fusion (e.g., SLS,
Layering polymer filaments. liquid resin with light or laser. SLM): Using lasers to sinter or
melt powder.
Laminated Object Manufacturing Directed Energy Deposition (DED): Material and Binder Jetting:
(LOM): layering and bonding thin uses a focused energy source to inkjet technology to deposit
sheets of material, such as melt material as it is deposited layer material droplets for 3D printing.
paper, plastic, or metal. by layer
Case Study: 3D Printing in Aerospace
Problem Set:
Traditional methods: High material waste, longer production time, and
complex designs for certain parts.
AM Solution:
Reduced material waste, faster production times, and ability to create
complex, lightweight designs.
EXAMPLE
GE’s uses 3D printing for jet engine
components (like fuel nozzles).
-Speeds up production of 3D
printed jet engine parts by 25%!
Current Trends in AM for Aerospace:
1- High-Performance Materials for Aerospace:
-Titanium Alloys: light weight, strength, and heat
resistance.
-Nickel Alloys: Used in engine components where high
heat resistance is critical, especially in turbine blades.
2- Multi-Material Printing:
Combine multiple materials (metals, ceramics,
polymers) in a single 3D print to create more complex,
multi-functional parts.
NASA has been researching 3D printing for spacecraft
components, using AM to produce lighter parts with fewer
materials. They are focusing on creating heat shields and rocket
engine components using AM.
Key Aerospace Applications in AM
1- Engine Components: design parts with internal cooling channels, which
improves thermal efficiency.
2- Lightweight Structures: AM reduces the overall weight of aircraft
components
3- Engineers can now prototype components quickly, testing and iterating
designs at a fraction of the time and cost.
PREVIOUS EXPERIENCE
Prototype 1 VS Prototype 2
CONCLUSION
AM is reshaping industries with its unique capabilities and applications.
While currently a small segment of global manufacturing, its growth and potential are
immense.
“We don’t yet know the full possibilities
of additive manufacturing—it’s only the
beginning.”
