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Summary
Core Theme
Additive manufacturing, a key component of Industry 4.0, revolutionizes production by building objects layer by layer from various materials, offering new possibilities for design, prototyping, and end-use part creation.
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additive manufacturing is one of the
major advancements of industry 4.0 it is
comprised of several different processes
using a variety of materials to create
applications with new production
possibilities and solutions emerging as
we speak each process follows three
primary steps design slice and print a
design can be created from an original
concept utilizing computer-aided design
software or cad by selecting an existing
design through libraries or by scanning
an existing part with 3d scanning each
of these methods will then take the 3d
model and create an stl file the stl
file is then transferred to slicing
software which preps the model for the
final printing stage the model is sliced
into layers and a path will be generated
that the printer can understand a
variety of parameters can be adjusted
during this stage
manufacturing begins through one of the
3d printing processes in each process
material is added layer by layer in
additive manufacturing you're only using
the materials that are needed compared
to some traditional manufacturing
methods where the material is removed
and scrapped the materials utilized in
additive manufacturing are vast from
metals to sand and concrete to human tissue
tissue
let's take a look at each process and
which materials each supports
binder jetting printing process works by
applying a liquid bonding agent to a
powdered material first powdered
material either plastic metal glass sand
or ceramic is rolled out in a thin layer
the printhead then applies the binder to
the areas of the powdered material that
will become the final part the build
platform is lowered and the entire
surface is re-coated with fresh powder
this process is repeated again and again
to build up parts layer by layer
after the printing process is complete
the loose powder is removed and the 3d
printed part is extracted
directed energy deposition also known as
ded is essentially a form of buildup
welding the material either in powder or
wire form is melted by an energy source
while it's being deposited the process
repeats with each layer adhering to the
underlying layer the energy source can
be generated from a laser electron beam
electron arc or plasma directed energy
deposition can make new parts add
features or repair existing parts
material extrusion works similar to a
hot glue gun where glue is heated and
squeezed out as a liquid for material
extrusion a filament or pellet material
is heated and extruded through a nozzle
and deposited onto a build platform
layer by layer in more sophisticated
systems additional extruders can apply
different materials within the same
build with one material acting as a
support structure the capabilities of
material extrusion are diverse ranging
from consumer plastics to aerospace titanium
titanium
material jetting uses a process and
equipment similar to ink jet printing
but instead of dropping ink the
printhead selectively deposits droplets
of material onto the platform
an energy source such as a uv light is
then used to cure the layer before
dispensing the next layer this process
excels at producing parts and assemblies
with excellent detail and a relatively
smooth surface finish parts can be full
color or have multiple types of material
recent improvements in materials have
led to its adoption for indirect and
direct production of functional components
components
powder bed fusion is a process where
powder material is spread and a thermal
energy source such as a laser or
electron beam selectively fuses regions
of the build area
the build box is lowered and the powder
is re-coated continuing the process
layer by layer for polymer material the
powder surrounding the part acts as a
support enabling the production of
complex shapes and fine details
sheet lamination just like its name
indicates is a process where sheets of
material are stacked the boundary of the
layer is cut and bonded together to form
an object the sheet lamination process
has many forms and can utilize a wide
variety of materials such as paper
polymers and metals along with numerous
methods of bonding the layers of
material these bonding methods include
adhesives chemical heat and solid state
welding processes such as ultrasonic consolidation
consolidation
that photopolymerization gets its name
from its original form of using a large
vat of liquid photopolymer resin or
liquid plastic which solidifies when
exposed to a strong light source the
light source selectively cures a layer
of the liquid material and the platform
and part moves together to let uncured
material coat the next level that
polymerization is typically regarded to
be the highest resolution am process and
is capable of producing parts with
extraordinarily fine details
these advanced manufacturing techniques
are just scratching the surface of
what's possible additive manufacturing
is used to create prototypes and models
it's used in tooling for repairs and in
the creation of end usable parts
just 30 plus years young additive
manufacturing is still in the early
stages of development in industry 4.0
what is is constantly changing and
evolving so what's to come is beyond our
imaginations or is it
additive manufacturing has recalibrated
what's possible in the minds of those
who embrace it we encourage you to
explore projects here at america makes
maybe you'll be the next to create what
will be thank you for visiting the
nation's leading institute for the
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