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Additive Manufacturing Technologies， I Gibson, D W Rosen, B Stuc....pdf
cover-large.JPG
front-matter.pdf
fulltext.pdf
Chapter 1: Introduction and Basic Principles
What is Additive Manufacturing?
What Are AM Parts Used For?
The Generic AM Process
Step 1: CAD
Step 2: Conversion to STL
Step 3: Transfer to AM Machine and STL File Manipulation
Step 4: Machine Setup
Step 5: Build
Step 6: Removal
Step 7: Postprocessing
Step 8: Application
Why Use the Term Additive Manufacturing?
Automated Fabrication (Autofab)
Freeform Fabrication or Solid Freeform Fabrication
Additive Manufacturing or Layer-based Manufacturing
Stereolithography or 3D Printing
Rapid Prototyping
The Benefits of AM
Distinction Between AM and CNC Machining
Material
Speed
Complexity
Accuracy
Geometry
Programming
Other Related Technologies
Reverse Engineering Technology
Computer-Aided Engineering
Haptic-Based CAD
About This Book
Exercises
References
fulltext_001.pdf
2: Development of Additive Manufacturing Technology
Introduction
Computers
Computer-Aided Design Technology
Other Associated Technologies
Lasers
Printing Technologies
Programmable Logic Controllers
Materials
Computer Numerically Controlled Machining
The Use of Layers
Classification of AM Processes
Liquid Polymer Systems
Discrete Particle Systems
Molten Material Systems
Solid Sheet Systems
New AM Classification Schemes
Metal Systems
Hybrid Systems
Milestones in AM Development
AM Around the World
The Future? Rapid Prototyping Develops into Direct Digital Manufacturing
Exercises
References
fulltext_002.pdf
Chapter 3: Generalized Additive Manufacturing Process Chain
Introduction
The Eight Steps in Additive Manufacture
Step 1: Conceptualization and CAD
Step 2: Conversion to STL
Step 3: Transfer to AM Machine and STL File Manipulation
Step 4: Machine Setup
Step 5: Build
Step 6: Removal and Cleanup
Step 7: Post-process
Step 8: Application
Variations from One AM Machine to Another
Photopolymer-Based Systems
Powder-Based Systems
Molten Material Systems
Solid Sheets
Metal Systems
The Use of Substrates
Energy Density
Weight
Accuracy
Speed
Maintenance of Equipment
Materials Handling Issues
Design for AM
Part Orientation
Removal of Supports
Hollowing Out Parts
Inclusion of Undercuts and Other Manufacturing Constraining Features
Interlocking Features
Reduction of Part Count in an Assembly
Identification Markings/Numbers
Application Areas That Don´t Involve Conventional CAD Modeling
Medical Modeling
Reverse Engineering Data
Architectural Modeling
Further Discussion
Exercises
References
fulltext_003.pdf
Chapter 4: Photopolymerization Processes
Introduction
Photopolymerization Materials
UV Curable Photopolymers
Overview of Photopolymer Chemistry
Resin Formulations and Reaction Mechanisms
Photoinitiator System
Monomer Formulations
Interpenetrating Polymer Network Formation
Reaction Rates
Vector Scan SL
SL Process Overview
SL Machines
SL Resin Curing Process
Irradiance and Exposure
Laser-Resin Interaction
Photospeed
Time Scales
SL Scan Patterns
Layer-Based Build Phenomena and Errors
WEAVE
STAR-WEAVE
ACES Scan Pattern
Vector Scan Microstereolithography
Mask Projection Photopolymerization Technologies and Processes
Mask Projection SL Technology
Commercial MPSL Systems
MPSL Modeling
Two-Photon SL
Summary
Exercises
References
fulltext_004.pdf
Chapter 5: Powder Bed Fusion Processes
Introduction
SLS Process Description
Powder Fusion Mechanisms
Solid-state Sintering
Chemically-induced Sintering
Liquid-phase Sintering and Partial Melting
Distinct Binder and Structural Materials
Separate Particles
Composite Particles
Coated Particles
Indistinct Binder and Structural Materials
Full Melting
Powder Handling
Powder Handling Challenges
Powder Handling Systems
Powder Recycling
Approaches to Metal and Ceramic Part Creation
Metal Parts
Ceramic Parts
Variants of Powder Bed Fusion Processes
Laser-based Systems for Low-temperature Processing
Laser-based Systems for Metals and Ceramics
Electron Beam Melting
Line-wise and Layer-wise PBF Processes
Process Parameters
Applied Energy Correlations and Scan Patterns
Typical Materials and Applications
Materials
Capabilities and Limitations
Conclusions
Exercises
References
fulltext_005.pdf
Chapter 6: Extrusion-Based Systems
Introduction
Basic Principles
Material Loading
Liquification
Extrusion
Solidification
Positional Control
Bonding
Support Generation
Plotting and Path Control
Fused Deposition Modeling from Stratasys
FDM Machine Types
Materials
Limitations of FDM
Bioextrusion
Gel Formation
Melt Extrusion
Scaffold Architectures
Other Systems
Contour Crafting
Nonplanar Systems
FDM of Ceramics
Reprap and Fab@home
Exercises
References
fulltext_006.pdf
Chapter 7: Printing Processes
Evolution of Printing as an Additive Manufacturing Process
Historical Development of 3D Printing
Commercially Available Printing Machines
Advantages of Printing
Research Achievements in Printing Deposition
Polymers
Ceramics
Metals
Technical Challenges of Printing
Droplet Formation Technologies
Continuous Mode
Drop-on-Demand Mode
Other Droplet Formation Methods
Printing Process Modeling
Material Modification Methods
Hot Melt Deposition
Solution- and Dispersion-Based Deposition
Prepolymer Deposition
Three-Dimensional Printing
Technology
Commercial Machines
Other Materials
Advantages of Binder Printing
Exercises
References
fulltext_007.pdf
Chapter 8: Sheet Lamination Processes
Gluing or Adhesive Bonding
Bond-then-Form Processes
Form-then-Bond Processes
Thermal Bonding
Processes Based on Sheet Metal Clamping
Ultrasonic Consolidation
UC Bond Quality
UC Process Fundamentals
UC Process Parameters and Process Optimization
Oscillation Amplitude
Normal Force
Sonotrode Travel Speed
Preheat Temperature
Microstructures and Mechanical Properties of UC Parts
Defects
UC Microstructures
Mechanical Properties
Modeling of UC
UC Applications
Internal Features
Material Flexibility
Fiber Embedment
Smart Structures
Conclusions
Exercises
References
fulltext_008.pdf
Chapter 9: Beam Deposition Processes
Introduction
General Beam Deposition Process Description
Material Delivery
Powder Feeding
Wire Feeding
BD Systems
Process Parameters
Typical Materials and Microstructure
Processing-Structure-Properties Relationships
BD Benefits and Drawbacks
Exercises
References
fulltext_009.pdf
Chapter 10: Direct Write Technologies
Direct Write Technologies
Background
Ink-Based DW
Nozzle Dispensing Processes
Quill-Type Processes
Inkjet Printing Processes
Aerosol DW
Laser Transfer DW
Thermal Spray DW
Beam Deposition DW
Laser CVD
Focused Ion Beam CVD
Electron Beam CVD
Liquid-Phase Direct Deposition
Beam Tracing Approaches to Additive/Subtractive DW
Electron Beam Tracing
Focused Ion Beam Tracing
Laser Beam Tracing
Hybrid Technologies
Applications of Direct Write Technologies
Exercises
References
fulltext_010.pdf
Chapter 11: Design for Additive Manufacturing
Motivation
Design for Manufacturing and Assembly
Core DFAM Concepts and Objectives
Complex Geometry
Customized Geometry
Integrated Assemblies
Elimination of Conventional DFM Constraints
AM Unique Capabilities
Shape Complexity
Hierarchical Complexity
Functional Complexity
Material Complexity
Exploring Design Freedoms
Part Consolidation and Redesign
Hierarchical Structures
Industrial Design Applications
Design Tools for AM
Challenges for CAD
Solid-Modeling CAD Systems
Promising Technologies
Proposed DFAM System
Implicit Modeling
Search and Synthesis Methods
Cantilever Beam Example
Summary
Exercises
References
fulltext_011.pdf
Chapter 12: Guidelines for Process Selection
Introduction
Selection Methods for a Part
Decision Theory
Approaches to Determining Feasibility
Approaches to Selection
Selection Example
Challenges of Selection
Example System for Preliminary Selection
Production Planning and Control
Production Planning
Pre-processing
Part Build
Post-processing
Summary
Open Problems
Exercises
References
fulltext_012.pdf
Chapter 13: Software Issues for Additive Manufacturing
Introduction
Preparation of CAD Models - the STL File
STL File Format, Binary/ASCII
Creating STL Files from a CAD System
Calculation of Each Slice Profile
Technology Specific Elements
Problems with STL Files
STL File Manipulation
Viewers
STL Manipulation on the AM Machine
Beyond the STL File
Direct Slicing of the CAD Model
Color Models
Multiple Materials
Use of STL for Machining
Additional Software to Assist AM
Exercises
References
fulltext_013.pdf
Chapter 14: Direct Digital Manufacturing
Align Technology
Siemens and Phonak
Custom Soccer Shoes and Other DDM Examples
DDM Drivers
Manufacturing vs. Prototyping
Cost Estimation
Cost Model
Build Time Model
Stereolithography Example
Life-Cycle Costing
Future of Direct Digital Manufacturing
Exercises
References
fulltext_014.pdf
Chapter 15: Medical Applications for Additive Manufacture
Introduction
The Use of AM to Support Medical Applications
Surgical and Diagnostic Aids
Prosthetics Development
Manufacturing
Tissue Engineering and Organ Printing
Software Support for Medical Applications
Limitations of AM for Medical Applications
Speed
Cost
Accuracy
Materials
Ease of Use
Further Development of Medical AM Applications
Approvals
Insurance
Engineering Training
Location of the Technology
Service Bureaus
Exercises
References
fulltext_015.pdf
Chapter 16: Post-Processing
Support Material Removal
Natural Support Post-Processing
Synthetic Support Removal
Supports Made from the Build Material
Supports Made from Secondary Materials
Surface Texture Improvements
Accuracy Improvements
Error Sources
Model Pre-processing
Machining Strategy
Adaptive Raster Milling
Sharp Edge Contour Machining
Hole Drilling
Aesthetic Improvements
Preparation for use as a Pattern
Investment Casting Patterns
Sand Casting Patterns
Other Pattern Replication Methods
Property Enhancements using Non-thermal Techniques
Property Enhancements using Thermal Techniques
Conclusions
Exercises
References
fulltext_016.pdf
Chapter 17: The Use of Multiple Materials in Additive Manufacturing
Introduction
Multiple Material Approaches
Discrete Multiple Material Processes
Porous Multiple Material Processes
Blended Multiple Material Processes
Embedded Component AM
Commercial Applications Using Multiple Materials
Future Directions
Design Tools
Analysis
Multi-axis Systems
Materials Development
Applications
Conclusions
Exercises
References
fulltext_017.pdf
Chapter 18: Business Opportunities and Future Directions
Introduction
New Types of Products and Employment
New Types of Products
New Types of Employment
Digiproneurship
Conclusions
Exercises
References
back-matter.pdf
Additive Manufacturing Technologies
I. Gibson l D. W. Rosen l B. Stucker
Additive Manufacturing
Technologies
Rapid Prototyping to Direct Digital
Manufacturing
Dr. Ian Gibson
Department of Mechanical & Production
Engineering
National University of Singapore
9 Engineering Drive 1
Singapore 117576
Singapore
mpegi@nus.edu.sg
Dr. David W. Rosen
The George W. Woodruff School of
Mechanical Engineering
Georgia Institute of Technology
813 Ferst Drive, N.W.
Atlanta, GA 30332-0405
USA
david.rosen@me.gatech.edu
Dr. Brent Stucker
Department of Mechanical &
Aerospace Engineering
Utah State University
4130 Old Main Hall
Logan, UT 84322
USA
brent.stucker@usu.edu
ISBN: 978-1-4419-1119-3
DOI 10.1007/978-1-4419-1120-9
Springer New York Heidelberg Dordrecht London
e-ISBN: 978-1-4419-1120-9
Library of Congress Control Number: 2009934499
# Springer ScienceþBusiness Media, LLC 2010
All rights reserved. This work may not be translated or copied in whole or in part without the written
permission of the publisher (Springer Science+Business Media, LLC, 233 Spring Street, New York, NY
10013, USA), except for brief excerpts in connection with reviews or scholarly analysis. Use in
connection with any form of information storage and retrieval, electronic adaptation, computer
software, or by similar or dissimilar methodology now known or hereafter developed is forbidden.
The use in this publication of trade names, trademarks, service marks, and similar terms, even if they are
not identified as such, is not to be taken as an expression of opinion as to whether or not they are subject
to proprietary rights.
Cover design: The Cover Artwork is Courtesy of Bathsheba Grossman and Bathsheba Sculpture LLC
Printed on acid-free paper
Springer is part of Springer Science+Business Media (www.springer.com)
Preface
Thank you for taking the time to read this book on Additive Manufacturing (AM).
We hope you benefit from the time and effort it has taken putting it together and that
you think it was a worthwhile undertaking. It all started as a discussion at a
conference in Portugal when we realized that we were putting together books
with similar aims and objectives. Since we are friends as well as colleagues,
it seemed sensible that we join forces rather than compete; sharing the load and
playing to each others’ strengths undoubtedly means a better all-round effort and
result.
We wrote this book because we have all been working in the field of AM
for many years. Although none of us like to be called “old,” we do seem to have
decades of experience, collectively, and have each established reputations as
educators and researchers in this field. We have each seen the technologies
described in this book take shape and develop into serious commercial tools, with
tens of thousands of users and many millions of parts being made by AM machines
each year. AM is now being incorporated into curricula in many schools, poly-
technics and universities around the world. More and more students are becoming
aware of these technologies and yet, as we see it, there is no single text adequate for
such curricula. We hope that now, with this book, there is.
Additive Manufacturing is defined by a range of technologies that are capable of
translating virtual solid model data into physical models in a quick and easy
process. The data is broken down into a series of 2D cross-sections of a finite
thickness. These cross-sections are fed into AM machines so that they can be
combined, adding them together in a layer-by-layer sequence to form the physical
part. The geometry of the part is therefore clearly reproduced in the AM machine
without having to adjust for manufacturing processes, like attention to tooling,
undercuts, draft angles or other features. We can say therefore that the AM machine
is a What You See Is What You Build (WYSIWYB) process that is particularly
valuable the more complex the geometry is. This basic principle drives nearly all
AM machines, with variations in each technology in terms of the techniques used
for creating layers and in bonding them together. Further variations include speed,
v
vi
Preface
layer thickness, range of materials, accuracy, and of course cost. With so many
variables, it is clear to see why this book must be so long and detailed. Having said
that, we still feel there is much more we could have written about.
The first three chapters of this book provide a basic overview of AM processes.
Without fully describing each technology, we provide an appreciation for why AM
is so important to many branches of industry. We outline the rapid development of
this technology from humble beginnings that showed promise but still requiring
much development, to one that is now maturing and showing real benefit to product
development organizations. In reading these chapters, we hope you can learn the
basics of how AM works.
The next seven chapters (Chaps. 4–10) take each group of technologies in turn
and describe them in detail. The fundamentals of each technology are dealt with in
terms of the basic process, whether it is photopolymer curing, sintering, melting,
etc., so that the reader can appreciate what is needed in order to understand,
develop, and optimize each technology. Most technologies discussed in this book
have been commercialized by at least one company; and these machines are
described along with discussion on how to get the best out of them.
The final chapters deal with how to apply AM technology in different settings.
Firstly, we look at how the use of this technology has affected the design process
considering how we might improve our designs because of the WYSIWYB ap-
proach. Having said that, there are many options concerning the type of machine
you should buy in relation to your application, so we provide guidelines on how to
select the right technology for your purpose. Since all AM machines depend on
input from 3D CAD software, we go on to discuss how this process takes place.
These technologies have improved to the extent that many manufacturers are
using AM machine output for end-product use. Called Direct Digital Manufacturing,
this opens the door to many exciting and novel applications considered impossible,
infeasible or uneconomic in the past. We can now consider the possibility of mass
customization, where a product can be produced according to the tastes of an
individual consumer but at a cost-effective price. This moves us on nicely to the
subject of medical products made using AM where each part can be created accord-
ing to an individual patient’s data. Then we go on to discuss how to finish parts once
they come off the AM machine so that they can best suit the final application. We
complete the book with chapters on emerging areas of AM, with discussions on
multiple material and embedded systems, how these systems enable creative busi-
nesses and entrepreneurs to invent new products, and where AM will likely develop
in the future.
This book is primarily aimed at students and educators studying Additive
Manufacturing, either as a self-contained course or as a module within a larger
course on manufacturing technology. There is sufficient depth for an undergraduate
or graduate-level course, with many references to point the student further along the
path. Each chapter also has a number of exercise questions designed to test the
reader’s knowledge and to expand their thinking. Researchers into AM may also
find this text useful in helping them understand the state of the art and the
opportunities for further research.
Preface
vii
Although we have worked hard to make this book as comprehensive as
possible, we recognize that a book about such rapidly changing technology will
not be up-to-date for very long. With this in mind, and to help educators and
students better utilize this book, we will update our course website at http://www.
springer.com/978-1-4419-1119-3, with additional homework exercises and other aids
for educators. If you have comments, questions or suggestions for improvement, they
are welcome. We anticipate updating this book in the future, and we look forward to
hearing how you have used these materials and how we might improve this book.
As mentioned earlier, each author is an established expert
in Additive
Manufacturing with many years of research experience. In addition, in many
ways, this book is only possible due to the many students and colleagues with
whom we have collaborated over the years. To introduce you to the authors and
some of the others who have made this book possible, we will end this preface with
brief author biographies and acknowledgements.
Author Biographies
Dr. Brent Stucker is an Associate Professor of Mechanical & Aerospace
Engineering at Utah State University. After receiving his Ph.D. from Texas A&M
University in 1997, he joined the Industrial & Manufacturing Engineering faculty
of the University of Rhode Island, where he established the Rapid Manufacturing
Center. In 2002, he moved to Utah State, where he established and continues to lead
the Additive Manufacturing Laboratory. Dr. Stucker has taught courses on AM
technologies for more than 10 years, sits on the Rapid Technologies & Additive
Manufacturing Steering Committee for the Society of Manufacturing Engineers,
was a Selective Laser Sintering Users Group 2005 “Dinosaur Award” recipient, and
is the current Chairman of ASTM International’s Committee F42 on Additive
Manufacturing Technologies. His research focuses on metal AM, including Ultra-
sonic Consolidation, Direct Write, Laser Engineered Net Shaping, Selective Laser
Sintering, and their applications.
In 1995,
Prof. David W. Rosen is a Professor in the George W. Woodruff School of
Mechanical Engineering at the Georgia Institute of Technology. After receiving his
Ph.D. from the University of Massachusetts in 1992, he joined the faculty at
Georgia Tech.
the Rapid Prototyping & Manufacturing Institute
was started at Georgia Tech through an ARPA manufacturing education grant
and Dr. Rosen was asked to become its head. Since then, he has led the additive
manufacturing research and education program at Georgia Tech. He is active in the
Society of Manufacturing Engineers Direct Digital Manufacturing Tech Group and
the 3D Systems User Group conference. His research focuses on photopolymer
processing, ink-jet printing, and design for additive manufacturing.
Dr. Ian Gibson is an Associate Professor at
the National University of
Singapore (NUS). Originally from Scotland, he moved to England where he gained
a Ph.D. in robotics at Hull University. His teaching career started at Nottingham
University, where he specialized in advanced manufacturing technology and first
came to learn about the AM technology that was then called Rapid Prototyping.
ix
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