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Summary Additive Manufacturing Revision Poster
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Additive Manufacturing Revision Poster for ME20026 Manufacturing Operations and Technology
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ME20026: ADDITIVE MANUFACTURING TECHNOLOGIES:RAPID PROTOTYPING OR RAPID MANUFACTURING:
Stereolithography (SLA): Selective Laser Sintering (SLS) and Laminated Object Manufacturing:
COMPOSITES:
Liquid polymer cured selectively into solid Electron Beam Melting: (EBM): Layers of material (usually vinyl, plastic
Uses computer controlled additive Spray Layup and Hand Layup (Contact Moulding):
to createdistinct
component Non-metallic or metallic powder or paper) cut using computer controlled
Composite
machines material is combination of two or more chemically and Single mould is used
insoluble phases with a recognisable interface Platform that can be lowered andoraised Thus isalso referred sintered
to as
or melted using laser (SLS)
open-mould processing machines
Components often created layer by put in vat of polymer or electron beam (EBM) to achieve o Using lasers or cutters
Their
layerproperties and structural performance are generally superior to those
Platform is raised to highest position so desired shape Material is stacked on top of each other
of constituents acting
Sometimes known as layer basedindependently Hand layup
only thin layer of polymer covers it Thin layer of powder is deposited to form the object
Dispersed phasemethods
manufacturing or fibres generally made of o Simplest method of contact moulding
o Position a in part build area o Stacking may be manual or
o Glass o Materials are placed in proper order
Ultraviolet laser traces shape of Beam scans shape of layer to automatic
o Carbon o Brushed
bottommost layer of component sinter powder particles into a solid Cross-hatch pattern often cut into parts
o Boron o Shaped in mould by hand with a roller
o Cures polymer into solid Build area is lowered that will be removed
Fused Filament
Continuous Fabrication
phase or matrix(FFF): Squeezing action of layer
rollerof
expels trapped air bubbles and compacts the part
o Extruder head moves in two directions Platform is lowered so thin layer of Fresh powder is deposited o Simplifies removal of excess
Thermosets
over a table polymer covers part on top for next layer to be built material
o Thermoplastics Uses
Process is repeated until reaching topmost
o oMetals
Table can be lowered or raised as
o SLS
required layer of part
o Ceramics Plastics
o Position c
Reinforced
Filament,plastics
usually thermoplastic,
o EBM
extruded through small orifice or Possible to fabricate layers that have larger
Spray layup
o Aka Titanium andinto
cobalt-
heated die surface area on smaller layers o Moulding is done by spraying materials mould
Polymer-matrix composites (PMC) chrome alloys over mould surfaces
Complex geometries created one layer o Position b o Both resin and chopped fibres are sprayed
Fibre-reinforced plastics (FRP)
Generally weak support structureoinRolling shape deposited materials may be necessary in the process
o atHigh
a timespecific strength
o Through controlled motion of of perforated structure is manufactured
Strength to weight ratio
extrusion o Holds overhanging parts of component
o High specific head in relation to table
stiffness
o Through switching head on and off o Removed in post-processing
Stiffness to weight ratio
o When one layer is
Good fatigue resistancecomplete, the table is
o lowered
Easy tofor the next
design, to be and
fabricate builtrepair
Metal-matrix composites (MMC) Filament Winding:
o Higher toughness Resin and fibres combined at time of curing
o Higher ductility o Develops composite structure
o Higher resistance to elevated temperatures Parts produced onThree-Dimensional
rotating mandrel Printing
o Axisymmetric parts Printing head deposits binder onto layer of polymer, ceramic or metal powder
o More difficult to manufacture
Ceramic matrix composites (CMC) o Non-symmetric parts Build area is lowered
Reinforcing filament tape, o orSimilar to SLS
roving, is wrapped continuously around the form
o Offer highest resistance to elevated temperatures and corrosive
Reinforcements are impregnated
Another layer by of powder
passing themis deposited
through athen fusedbath
polymer by binder
environments
Process can be modified Process continues
by wrapping until all
mandrel layers
with have been
pre-preg manufactured
material
Strong products produced Process usingcan beprocess
this combined with sintering and metal infiltration
Techniques for manufacturing PMCs
o Due to highly o Produces
reinforced structuredenser and stronger parts
o Fibre impregnation
Includes o Can produce parts up to 4.5m diameter and 20m long
Prepregs Use
Sheet-moulding compound o Strengthening cylindrical or spherical pressure vessels made of materials such as aluminium and
Bulk-moulding compound titanium
Thick-moulding compound Presence of metal inner lining makes part impermeable
o Moulding of reinforced plastics
o Filament welding
o Pultrusion
o Pulforming
Many composites require to be cured
o Subject to controlled high temperatures
o Achieves peak strength after forming
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