Additive Manufacturing: A Clear Cut View- BLOG 1

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Additive Manufacturing(AM) is the process of fabricating the 3D model into required object by depositing the material layer by layer, also known as 3D printing. It is the is a revolutionary technology that is rapidly changing the way we design and manufacture products. Unlike traditional subtractive methods that remove material from a solid block, AM builds objects layer by layer using a variety of materials, including plastics, metals, ceramics, and even living cells.

Points to be noted for 3D Printing:

  1. Design the model
  2. convert the model into STL file
  3. Slicing
  4. Tessellation
  5. Type of Additive Manufacturing(AM)

STL File:

The STL file format is the key component of this procedure. The 3D object is represented in this file as a mesh-like arrangement of triangular facets. The surface geometry of the item is defined by the information that each facet contains about its points and normal vector. Because so many different 3D design and slicing programs use STL files, they are an essential part of the AM procedure.

Sample STL File [1]

Slicing:

Before printing, the STL file undergoes a process called slicing. This involves dividing the object into many thin layers, typically ranging from 0.05 to 0.3 mm in thickness. Each layer essentially becomes a 2D image that guides the material deposition process during printing.

Slicing[2]

Tessellation:

The slicing software further splits the 2D image into smaller shapes, or tessellations, within each layer. These tessellations, which specify the distinct routes or places where the material will be deposited, belong to the AM technology that has been selected. For instance, tessellations can stand in for the lines that the filament would be extruded along in material extrusion (FDM) printing, or they could stand in for the spots where the powder will be melted by the laser in powder bed fusion (SLS).


Tessellation[3]


Types of Additive Manufacturing Techniques:

There are many different types of AM technologies, each with its own advantages and limitations. Some of the most common types include:

Vat Photopolymerization (SLA): ๐Ÿ‘ˆThis technology uses an ultraviolet light source to cure a liquid resin layer by layer. It offers smooth surface finishes and high accuracy, making it ideal for creating prototypes and models.

Vat Photopolymerization[4]

Material Jetting:๐Ÿ‘ˆ This technology uses a jet of material to build the object layer by layer. It offers high speed and accuracy, making it suitable for industrial applications.

Material Jetting[5]


Binder Jetting:๐Ÿ‘ˆ This technology uses a binder to selectively bind powdered materials together. It is a relatively inexpensive technology that can be used to create large parts.

Binder Jetting[6]

Material Extrusion (FDM):๐Ÿ‘ˆ This is the most popular technology for hobbyists and small businesses. It works by extruding a filament of thermoplastic material through a heated nozzle to build the object layer by layer.

Material Extrusion[7]
Powder Bed Fusion :๐Ÿ‘ˆ This technology uses a laser or electron beam to melt and fuse metal or plastic powder particles layer by layer. It offers high resolution and accuracy, making it suitable for industrial applications.

Powder Bed Fusion[8]




Directed Energy Deposition (DED):๐Ÿ‘ˆ This technology uses a focused beam of energy to melt and deposit metal powder onto a substrate. It is capable of producing large, complex parts with high strength and durability.
 
Direct Energy Deposition[9]




Sheet Lamination: ๐Ÿ‘ˆThis technology builds objects by laminating sheets of material together. It is a relatively low-cost technology that can be used to create large parts with complex geometries.

Sheet Lamination[10]



Conclusion:

The choice of the most suitable AM technology depends on various factors such as the desired material properties, the required part size and complexity, and the production volume. By understanding the different types of AM technologies, STL files, slicing, tessellation, and one can make informed decisions and leverage the power of this transformative technology.

***In the upcoming blogs we will discuss the in depth of every AM techniques***

Note: The images are taken from the google images for better understanding of the readers and gave the appropriate references below....


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References:

  1. https://www-objects.markforged.com/craft/common/_small/STL-Sphere.png
  2. https://assets.epicurious.com/photos/593045d0b676c07b387fb46e/16:9/w_2560%2Cc_limit/HOW-TO-CUT-WATERMELLON-25052017-001.jpg
  3. https://media.istockphoto.com/id/1220443934/vector/vector-seamless-geometric-pattern-simple-abstract-lines-lattice-repeating-elements-stylish.jpg?s=612x612&w=0&k=20&c=G67a3yJG5nQzg5kgU3m545InxCE69tuMOBlGi7jceYY=
  4. https://www.lboro.ac.uk/media/wwwlboroacuk/external/content/research/amrg/powderbedfusion%20-%20process.jpg
  5. https://www.lboro.ac.uk/media/wwwlboroacuk/external/content/research/amrg/material_jetting_process.jpg
  6. https://www.lboro.ac.uk/media/wwwlboroacuk/external/content/research/amrg/binderjetting-process.jpg
  7. https://www.lboro.ac.uk/media/wwwlboroacuk/external/content/research/amrg/material%20extrusion%20-%20process.jpg
  8. https://www.lboro.ac.uk/media/wwwlboroacuk/external/content/research/amrg/sheetlamination%20-%20process.jpg
  9. https://www.lboro.ac.uk/media/wwwlboroacuk/external/content/research/amrg/vat-process.jpg
  10. https://www.lboro.ac.uk/media/wwwlboroacuk/external/content/research/amrg/Direct%20Energy%20Deposition%20-%20process.jpg


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