Additive Manufacturing

3.

Additive Manufacturing Processes and Technologies

3.1.

Vat Photopolymerization

3.1.1.

Principle of Operation

3.1.2.

Stereolithography

3.1.2.1.

Process Details

3.1.2.2.

Equipment Components

3.1.2.3.

Build Parameters

3.1.3.

Digital Light Processing

3.1.3.1.

Process Differences from SLA

3.1.3.2.

Advantages and Limitations

3.1.4.

Continuous Liquid Interface Production

3.1.4.1.

CLIP Technology

3.1.4.2.

Speed Advantages

3.1.5.

3.1.5.1.

Standard Resins

3.1.5.2.

Engineering Resins

3.1.5.3.

Biocompatible Resins

3.1.5.4.

Specialty Resins

3.1.6.

3.1.6.1.

High Resolution

3.1.6.2.

Smooth Surface Finish

3.1.6.3.

Fine Feature Reproduction

3.1.7.

3.1.7.1.

Material Properties

3.1.7.2.

Post-Curing Requirements

3.1.7.3.

Limited Mechanical Strength

3.1.7.4.

Build Volume Constraints

3.2.

Material Extrusion

3.2.1.

Principle of Operation

3.2.2.

Fused Deposition Modeling

3.2.2.1.

Process Details

3.2.2.2.

Equipment Components

3.2.2.3.

Build Parameters

3.2.3.

Fused Filament Fabrication

3.2.3.1.

Terminology Differences

3.2.3.2.

Open Source Development

3.2.4.

3.2.4.1.

Standard Thermoplastics

3.2.4.1.1.

PLA Properties and Applications

3.2.4.1.2.

ABS Properties and Applications

3.2.4.1.3.

PETG Properties and Applications

3.2.4.2.

High-Performance Polymers

3.2.4.2.1.

PEEK Applications

3.2.4.2.2.

PEI/ULTEM Applications

3.2.4.3.

Composite Materials

3.2.4.3.1.

Carbon Fiber Filled Polymers

3.2.4.3.2.

Glass Fiber Filled Polymers

3.2.4.3.3.

Metal Filled Polymers

3.2.5.

3.2.5.1.

3.2.5.2.

Wide Material Variety

3.2.5.3.

Simplicity and Accessibility

3.2.5.4.

Large Build Volumes

3.2.6.

3.2.6.1.

Lower Resolution

3.2.6.2.

Anisotropic Strength

3.2.6.3.

Warping and Layer Adhesion Issues

3.2.6.4.

Support Structure Requirements

3.3.

Powder Bed Fusion

3.3.1.

Principle of Operation

3.3.2.

Polymer-Based PBF

3.3.2.1.

Selective Laser Sintering

3.3.2.1.1.

Process Details

3.3.2.1.2.

Equipment Components

3.3.2.1.3.

Build Parameters

3.3.2.2.

Multi Jet Fusion

3.3.2.2.1.

3.3.2.2.2.

Process Advantages

3.3.3.

Metal-Based PBF

3.3.3.1.

Selective Laser Melting

3.3.3.1.1.

Process Details

3.3.3.1.2.

3.3.3.2.

Direct Metal Laser Sintering

3.3.3.2.1.

Process Variations

3.3.3.3.

Electron Beam Melting

3.3.3.3.1.

Vacuum Environment

3.3.3.3.2.

High-Temperature Processing

3.3.4.

3.3.4.1.

Polymer Powders

3.3.4.1.1.

3.3.4.1.2.

PA12 Properties

3.3.4.2.

3.3.4.2.1.

Titanium Alloys

3.3.4.2.2.

Aluminum Alloys

3.3.4.2.3.

3.3.4.3.

Ceramic Powders

3.3.5.

3.3.5.1.

High Strength Parts

3.3.5.2.

Complex Geometries

3.3.5.3.

No Support Structures for Polymers

3.3.5.4.

Good Surface Quality

3.3.6.

3.3.6.1.

Surface Roughness for Metals

3.3.6.2.

Powder Handling and Safety

3.3.6.3.

High Equipment Cost

3.3.6.4.

Residual Stress and Warping

3.4.

Material Jetting

3.4.1.

Principle of Operation

3.4.2.

Standard Material Jetting

3.4.2.1.

Inkjet Technology Adaptation

3.4.2.2.

Multi-Material Capabilities

3.4.3.

NanoParticle Jetting

3.4.3.1.

Metal Nanoparticle Deposition

3.4.3.2.

Sintering Process

3.4.4.

Drop-On-Demand Systems

3.4.4.1.

Precision Control

3.4.4.2.

Material Efficiency

3.4.5.

3.4.5.1.

3.4.5.2.

3.4.5.3.

Metal Nanoparticles

3.4.6.

3.4.6.1.

3.4.6.2.

Multi-Material Printing

3.4.6.3.

Multi-Color Printing

3.4.6.4.

Smooth Surface Finish

3.4.7.

3.4.7.1.

Limited Material Properties

3.4.7.2.

3.4.7.3.

Limited Mechanical Strength

3.4.7.4.

Small Build Volumes

3.5.

3.5.1.

Principle of Operation

3.5.2.

3.5.2.1.

Powder Spreading

3.5.2.2.

Binder Deposition

3.5.2.3.

Layer Repetition

3.5.2.4.

Green Part Handling

3.5.3.

Post-Processing Steps

3.5.3.1.

3.5.3.2.

3.5.3.3.

3.5.4.

3.5.4.1.

3.5.4.2.

Sand for Casting

3.5.4.3.

Ceramic Powders

3.5.5.

3.5.5.1.

3.5.5.2.

Large Build Volumes

3.5.5.3.

Lower Cost for Metal Parts

3.5.5.4.

No Thermal Stress During Build

3.5.6.

3.5.6.1.

3.5.6.2.

Extensive Post-Processing

3.5.6.3.

Lower Mechanical Properties

3.5.6.4.

Dimensional Changes During Sintering

3.6.

Directed Energy Deposition

3.6.1.

Principle of Operation

3.6.2.

Laser-Based Systems

3.6.2.1.

Laser Engineered Net Shaping

3.6.2.2.

Powder Feed Systems

3.6.2.3.

Wire Feed Systems

3.6.3.

Electron Beam Systems

3.6.3.1.

Electron Beam Additive Manufacturing

3.6.3.2.

Vacuum Environment Requirements

3.6.4.

Arc-Based Systems

3.6.4.1.

Wire Arc Additive Manufacturing

3.6.4.2.

Welding Technology Integration

3.6.5.

3.6.5.1.

3.6.5.2.

3.6.5.3.

Specialty Alloys

3.6.6.

3.6.6.1.

Large Part Creation

3.6.6.2.

Repair Applications

3.6.6.3.

High Deposition Rate

3.6.6.4.

Multi-Material Capability

3.6.7.

3.6.7.1.

3.6.7.2.

Rough Surface Finish

3.6.7.3.

Complex Process Control

3.6.7.4.

Limited Geometric Complexity

3.7.

Sheet Lamination

3.7.1.

Principle of Operation

3.7.2.

Laminated Object Manufacturing

3.7.2.1.

Paper-Based Systems

3.7.2.2.

Adhesive Bonding

3.7.3.

Ultrasonic Additive Manufacturing

3.7.3.1.

Metal Foil Bonding

3.7.3.2.

Ultrasonic Welding

3.7.4.

3.7.4.1.

3.7.4.2.

3.7.4.3.

3.7.5.

3.7.5.1.

3.7.5.2.

Fast Build Speed

3.7.5.3.

Large Build Volumes

3.7.6.

3.7.6.1.

3.7.6.2.

Delamination Risk

3.7.6.3.

Limited Geometric Complexity

3.7.6.4.

Anisotropic Properties

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2. Digital Workflow for Additive Manufacturing

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4. Materials for Additive Manufacturing