Notes 3D - Modeling, Lecture 4
3D - Modelleren (WB1633-15)
Technische Universiteit Delft
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Adapted from: utwente/ctw/opm/research/design_engineering/rm/RM%20processes/
Ir. J.J. Neve, dec 2013
Overview of major AM Processes
additive manufacturing (AM) 1 : a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. Synonyms: additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing, and freeform fabrication.
There are many different Additive Manufacturing (AM) processes, all with their specific benefits, drawbacks and application areas. According to ASTM F2792‐ 121 the currently available AM processes are divided into 7 groups:
- Material Extrusion
- Material Jetting
- Binder Jetting
- Sheet lamination
- Vat photo polymerization
- Powder bed fusion
- Direct Energy Deposition
This page will give an overview of some mainstream AM methods. Please be aware that new AM techniques are developed yearly, while new production machines, especially those focused on home‐ use, are presented on a weekly basis. As there are many techniques, there are also many ways they can be classified. This classification is based on the method used for making the layers.
1 ASTM F2792‐12a Standard Terminology for Additive Manufacturing Technologies, ASTM
International, sep 2012
Material Extrusion (FDM)
Material Extrusion is a group of AM processes that create the final product by selectively depositing material. They do so by extruding the material through a small diameter nozzle. The base material often is a paste or a plastic. In the case of the paste a syringe type applicator can be used to deposited the paste. For plastics usually a plastic filament is fed through a heated nozzle that melts the plastic so it can be deposited.
Fused Deposition Modeling (FDM) (trademark of Stratasys) is a process that uses a reel of plastic filament. Once deposited the heated filament will stick to underlying layers and neighboring filaments and will almost directly solidify. Due to the nature of the FDM process overhanging features should be held by support material
Fused Deposition Modeling showing the part (dark blue) and support material (light blue). The extrusion head (see detailed view at the upper right) remains at the same z‐level and the build platform moves to allow stacking layers. Picture source: custompartnet/wu/fused‐deposition‐modeling
Due to the simplicity of the layout of the process and the machine, FDM is used in preferably used in the many homebuilt 3D print machines like for example the RepRap and the Ultimaker.
Binder jetting (Z‐corp, Voxeljet)
In the binder jetting process group the product material is in a powdered form and the inkjet head is used to locally disperse glue, thus binding the powders locally. Typically two bins are used, a bin were the product is formed and an extra bin with fresh powder. After the powder in a layer has been solidified using the glue, the build container is lowered en the powder bin is raised. A roller or a doctor blade is used to move the powder from the storage bin to the build bin. A big advantage of this method is that all kinds of powders can be used, albeit only one powder type per build. Also it is very easy to add colour to the printed final products. If no other post processing steps are used (for example oven sintering or resin impregnation) the final product is not very strong.
The binder jetting process. Picture source: custompartnet/wu/3d‐printing
Sheet lamination (LOM, PLT)
Sheet Lamination is a group of processes that create a layer by cutting the contours of the layer. Laminated Object Manufacturing (LOM) does so by stacking plastic sheet material on top on the sheets below and for uses a computer controlled cutting device (laser, knife) to cut the lines that form the edges of the desired shape. When the product has been printed the excess material is removed. Paper Lamination Technology (PLT) uses especially develop paper sheets instead of plastic ; successive layers are glued to each other by thermally activated glue.
Principle of Laminated Object Manufacturing (LOM) using rolls of product material (left) and a cutting laser. Picture source: mechanicalengineeringblog
Powder bed fusion (SLS, SLM, EBM)
Powder bed based methods use two (or three) powder beds filled with power that will be used as product material. The layers are created in one of the beds by using thermal energy to locally bind the power in the top layer of the bed. After a layer is finished, the bed in which the product is created, is lowered and new powder is swept from to second bed onto the building bed. Many powders can be used in this type of process; the only demand is that heating the powder will result in local binding of the powder. Selective laser sintering (SLS) is used to locally sinter plastic or metal powders; a laser is used as the heat source and the resulting products is still partly porous. Selective laser melting (SLM) uses a laser to fully melt the metal powder. Finally Electron Beam Melting uses and electron beam instead of a laser. Powder bed fusion systems are the most used AM production process. An advantage of powder bed based methods (3D printing and SLS) is that the powder also serves as support material, so usually no support structures have to be built. For SLM, due to the liquidity of the melt, support structures are still required.
Selective Laser Sintering (SLS) using a 3 bin system. Picture source: custompartnet/wu/selective‐laser‐sintering
Direct Energy Deposition
Direct Energy Deposition is a group of processes process where the material is directly deposited on the final location in the product. It does so by jetting the build material into the heated zone, created by a laser, electron beam or an ionized gas. As with the other methods that jet the product material, DED can change the product material easily, thus allowing for the graded functional materials.
The Laser Engineered Net Shaping (LENS) process Picture source: rpmandassociates/
Notes 3D - Modeling, Lecture 4
Vak: 3D - Modelleren (WB1633-15)
Universiteit: Technische Universiteit Delft
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Aanbevolen voor jou
Andere studenten bekeken ook
- WB3Dmodeleren - 8.9
- Colleges Q2
- C1-4 massatraagheid
- TCD3-WB38 - De opdracht is om zelfstandig met je groep een mechanische karretje te ontwerpen en te realiseren dat in de kortste tijd een afstand van 5 meter overbrugt en vervolgens weer zo snel mogelijk tot stilstand komt.
- Several 3D printing capabilities
- Aantekeningen 3D - Modelleren, college 7