Introduction
Relevance of Additive
Manufacturing/Rapid
Prototyping in Present
Manufacturing
scenario
P Saha Mech. Engg. Dept. IITKGP
Benefits of reaching the marketplace
faster than the competitors
P Saha Mech. Engg. Dept. IITKGP
Why rapid-to-market?
Rapid-to-market company
has a longer sales life for the product
gains a pricing advantage.
can start product development later , therefore can
use more up-to-date technology to develop that
product, reduced cost of production, better
features and (quality)
has a marketplace advantage by gaining customers
who may potentially become loyal customers.
P Saha Mech. Engg. Dept. IITKGP
Manufacturing environment in 2030
Changing perception of products
Individual customization is a possibility
Shorter product life cycle
Easily re-configurable products to meet changing
needs
Global markets and competition are forcing
manufacturing companies to rapidly respond to
changing market needs
Technological advances would open up a whole range
of new possibilities and operational methods
The impact of the internet and information technology
will enable manufacturing to be a data-intensive
activity and a knowledge-intensive process.
P Saha Mech. Engg. Dept. IITKGP
Traditional Prototyping: Subtractive
approach through CNC milling
CNC milling the top of a scale model of car in tooling board.
After first roughing, the actual surface is milled.
P Saha Mech. Engg. Dept. IITKGP
Layered manufacturing through
material addition process
Building-up structures with layers is
not a new idea
e.g. Pyramids: but hardly any
automated construction
P Saha Mech. Engg. Dept. IITKGP
Modern tools & technology leads to
Additive Manufacturing
Additive Manufacturing is also known as
Rapid Manufacturing
Rapid Prototyping
Solid Freeform Fabrication
Direct Digital Manufacturing
3-D Printing
P Saha Mech. Engg. Dept. IITKGP
Impact of Advancements of Manufacturing
Technology
P Saha Mech. Engg. Dept. IITKGP
Layered manufacturing
Modern manufacturing was made possible
by several enabling technologies
CAD-based solid modeller
High energy density source
like laser, electron beam
Ink-jet printing
High-performance motion controller
Integrated with traditional
manufacturing processes
P Saha Mech. Engg. Dept. IITKGP
Additive Manufacturing
/Rapid Prototyping
It is a freeform fabrication technique by which
a total object of prescribed shape, dimension
and finish can be directly generated from the
CAD-based geometric model stored in a
computer, without human intervention.
P Saha Mech. Engg. Dept. IITKGP
Layered manufacturing
Effect of stair-stepping as a function of layer
thickness
P Saha Mech. Engg. Dept. IITKGP
Basic Elements for Processing of CAD Data
in An Additive Manufacturing System
A solid 3D
CAD model
Decomposed
into cross-
sectional layers
Generates trajectories for
guiding material additive
processes to physically build
up these layers in an
automated fabrication
Sacrificial supporting machine
layers are also
simultaneously built
up to fixture the
object
P Saha Mech. Engg. Dept. IITKGP
Use support structures only
where required, i.e., for the
unconnected regions and
steep overhanging features
These explicit support structures may
be deposited with the same material as
the object being formed, but are drawn
out in a semisolid fashion so that they
are easy to remove once the part is
completed, e.g., they may be deposited
as thin wall structures
P Saha Mech. Engg. Dept. IITKGP
RP Process sequence
P Saha Mech. Engg. Dept. IITKGP
Additive Manufacturing Techniques
(AM techniques)
Can build arbitrary complex 3D geometries. no
requirement of featured-based design.
Process planning is automatic based on the CAD
model.
The shape decomposition maps complex 3D-
geometry in 2½-D representation.
Does not require part-specific fixture or tooling.
Minimal or no human intervention to operate.
P Saha Mech. Engg. Dept. IITKGP
Possible formation of Isolated
Island during slicing process
P Saha Mech. Engg. Dept. IITKGP
Steps in obtaining finished part in
additive manufacturing
P Saha Mech. Engg. Dept. IITKGP
Various Types of Supports
P Saha Mech. Engg. Dept. IITKGP
Effect of Stair-stepping as a
function of layer thickness
P Saha Mech. Engg. Dept. IITKGP
Effect of Build Orientation on
Accuracy and Finish
P Saha Mech. Engg. Dept. IITKGP
Effect of Part Orientation on
Trapped Volume
P Saha Mech. Engg. Dept. IITKGP
Steps in obtaining finished part in
additive manufacturing
P Saha Mech. Engg. Dept. IITKGP
Information Flow in Additive
Manufacturing (AM)
Data Creation Part Build Specialised RP
3D CAD Software
Package File
2D Slice Data
Generation
CAD Interface Data Export
to STL
Specialised RP
Software
Data
Specialised RP Validation and
Software Repair Setting Up of
Process Specialised RP
Parameters Software
Specialised RP Part
Software Orientation
and Scaling Support Specialised RP
Structure Software
Generation
P Saha Mech. Engg. Dept. IITKGP
Classification of AM Processes
Additive Manufacturing
Processes
(Material addition/ creation
type processes)
By Material By Material
Conversion Addition
In
Liquid to Powder to In Layers Points/
Solid Solid Lines
P Saha Mech. Engg. Dept. IITKGP
Classification of AM Processes
Principles of Creation of
GMP
Transformation Lamination Addition of
Transformation from powder to process (addition materials
from liquid to solid solid of materials/ foils/ (melting)
sheets) & cutting
the outer contour
By sintering By applying
selectively binder In points In lines
selectively
Curing Solidification
photopolymers of fluids by
by UV laser electric field
P Saha Mech. Engg. Dept. IITKGP
Integration of Input, Method and Material
in Additive Manufacturing
P Saha Mech. Engg. Dept. IITKGP
Process Chain for AM
ProductDevelopment
Input for CAD Methods for Prototyping
P Saha Mech. Engg. Dept. IITKGP
Integration of computer tools for
advanced product development
Product Development Phases
Computer Analysis Concept Preliminary Detail Production
Tools Design Design
CAD - Detail Layout Detailing -
critical
subsystems
CAE Analyse Analyse System Components Process
critical sub- performance analysis analysis simulation
systems
CAM - STL/RP STL/RP Additive Manufacturing
manufact. process
development
Prototype
Manufacture - Critical System (material & System (Mat’l,
AM, CNC) components breadboard functional) functional and
manufacture)
Verify critical
CMM Measure Verify critical --- dimension Verify critical
System/ dimensions dimension
sub-systems System Quality
Testing System Subsystem System performance assurance &
performance performance function & reliability certification
P Saha Mech. Engg. Dept. IITKGP
Reverse engineering (RE)
Typical applications
Creating data for part for which there is no CAD data,
or for which the data has become obsolete or lost.
Inspection and/or quality qontrol - Comparing a
fabricated part to its CAD description or to a standard
item.
Creating 3D data from a model or sculpture for
animation in games and movies.
Creating 3D data from an individual, model or sculpture
for creating, scaling or reproducing artwork.
P Saha Mech. Engg. Dept. IITKGP
Different Digitizing Techniques
for Existing Objects
A Faro arm in use, tipped
with an EIOS Mini-Moire
A touch probe developed
by Renishaw
P Saha Mech. Engg. Dept. IITKGP
Case study – head of a man
Point cloud Surface data
Object Rubber toy – Action man head
Scanning mode Rotary scanning
Scanning area Height direction 0 to 4 inches, Circumferential 0 to 360 degrees
Scanning pitch Height direction 0.008 mm, Circumferential pitch 0.008 mm
Scanning time Approximately 30 minutes
Dr. Picza format 56.50 MB
Data size
IGES formatMech. Engg.
P Saha 08.17
Dept.MBIITKGP
A Perfect Helmet for Formula 1 Driver
Maker : Schuberth Engineering AG, Germany
Measuring images
ATOS digitization
Special helmet: Measuring
for data transformation into
the coordinate system of the
Measured and helmet data helmet
P Saha Mech. Engg. Dept. IITKGP
Prominent RP processes
Stereo lithography (SLA)
Selective laser sintering (SLS)
Fused deposition modeling (FDM)
Laminated object manufacturing (LOM)
Three dimensional printing (3DP)
Laser engineered net shaping (LENS)
Electron beam melting (EBM)
P Saha Mech. Engg. Dept. IITKGP
