This is the presentation which I presented for my talk on the 'Advancements of Additive Manufacturing' which was conducted by Bangalore Institute of Technology as a 5 day Faculty Development program. We received a great response and had about 300 attendees across the country.
The presentation covers a few upcoming and interesting developments in the field of 3D Printing. There is a lot of innovation happening around but tried to compile the most interesting developments for the hour long presentation.
Open to any feedback and suggestions!
2. What is Additive Manufacturing?
• Additive Manufacturing refers to a
process by which digital 3D design
data is used to build up a
component in layers by depositing
material.
• Objects can be of almost any shape
or geometry and are produced
from digital model data.
• It has a wide variety of
technologies, materials and
finishes available.
• Can be used for short batch
manufacturing and customized
parts.
4. FUSED DEPOSITION MODELLING ( FDM ) :
WORKING PRINCIPLE :
A plastic filament is extruded from a hot end which heats it to the melting point and it
solidifies at room temperature once extruded.
SUPPORT
STRUCTURES
6. STEREOLITHOGRAPHY( SLA ) :
WORKING PRINCIPLE :
An ultraviolet laser is used to cure a photosensitive resin in a layer by layer format to
build the part. The path the laser traces solidifies in each layer.
SUPPORT
STRUCTURES
8. SELECTIVE LASER SINTERING( SLS ) :
WORKING PRINCIPLE :
A high power carbon dioxide laser is used to fuse small particles of polymer powder to
create these parts.
SELF SUPPORTED
BY POWDER
10. DIRECT METAL LASER SINTERING( DMLS ) :
WORKING PRINCIPLE :
A 200 watt ytterbium – fiber laser is used to fuse small particles of metal powder to
create these parts.
SUPPORT
STRUCTURES
13. HISTORY OF ADDITIVE MANUFACTURING :
YEAR : 1981
TECHNOLOGY : Stereolithography
COUNTRY : Japan
Due to issues with funding, was not
able to complete the patent
process before the one-year
deadline.
HIDEO KODAMA ALAIN LE MÉHAUTÉ
YEAR : 1984
TECHNOLOGY : Stereolithography
COUNTRY : France
Filed for a patent in 1984, but
without proper funding, abandoned
the project due to lack of
applications.
YEAR : 1984 ( 3 weeks after Alain )
TECHNOLOGY : Stereolithography
COUNTRY : USA
Filed for a patent in 1984, and was
granted in 1986. He founded the
company 3D Systems which is a
leader today in SLA machines.
CHARLES HULL
14. HISTORY OF ADDITIVE MANUFACTURING :
YEAR : 1988
TECHNOLOGY : Selective Laser Sintering
COUNTRY : USA
At his lab in Austin, conducted
experiments and succeeded. His
first SLS printer was called ‘Betsy’.
CARL DECKARD JOE BEAMAN
YEAR : 1989
TECHNOLOGY : Fused Deposition Modelling
COUNTRY : USA
Filed for a patent in 1989. He cofounded
the company Stratasys which is a leader
today in FDM machines.
SCOTT CRUMP
YEAR : 1988
TECHNOLOGY : Selective Laser Sintering
COUNTRY : USA
Along with Carl Deckard, he started
a SLS machine manufacturing
company called ‘Nova Automation’
17. TOPOLOGY OPTIMIZATION:
• It is a process of design where the
product is analyzed for removal of
excess material.
• The outer form of the object is
maintained through the process of
topology optimization while maintaining
boundary load conditions.
21. 3D PRINTED PISTONS:
• Freedom to create Bionic Designs which
involves inspiration from methods and
structures available in nature.
• Internal cooling channel has been
created to improve heat transfer and
increase performance.
• Pistons can be manufactured on
demand which avoids stocking up an
inventory.
• This design has led to a weight reduction
by 10% and an added performance of 30
BHP.
26. HARP – AZUL 3D:
• HARP stands for High Area Rapid
Prototyping and is developed by
researchers at Northwestern University,
Illinois.
• It is a type of Digital Light Processing
conceptually. But is much faster and has
various material options.
• Claims to print 457.2mm per hour with a
build volume of 304 x 304 x 1219 mm.
• It uses fluorinated oil which acts like
liquid Teflon and is passed over the
projection window to remove heat
which enables its speed.
31. MARSHA – AI SPACEFACTORY:
• This team won Nasa’s 3D Printed
habitat contest and secured 500,000 $.
• They built a 15 foot tall prototype of
Marsha using a 3D printer in over 30
hours and 3 days without human
assistance.
• With a vision to colonize mars, they are
creating a large scale FDM printer for
being able to create these vertical pods.
• These pods will soon be available to
stay in New York at prices varying from
175$ to 500$.
32. MARSHA – AI SPACEFACTORY:
• In terms of choice of materials, they are
using a mixture of Basalt fiber and
Polylactic Acid(PLA).
• Basalt fiber can be extracted from
Martian Rock and can be processed
from plants grown on Mars.
• This recyclable polymer composite has
outperformed concrete in Nasa’s
strength , durability and crush testing.
• It is 3 times more durable in
compression and 5 times more durable
than concrete in freeze thaw
conditions.
36. RELATIVITY SPACE:
• A company which uses the process of
Direct energy deposition (DED) to
build its fully 3D printed rockets.
• They use a type of DED which involves
a metal wire and a high power laser to
melt and deposit that material.
• The printer they developed, ‘Stargate’
uses robotic arms and needs no
human intervention while printing.
• They are able to shorten the time to
build a rocket to as low as 60 days and
drastically reduce part count.
42. ORGAN PRINTING:
• Researchers in Tel Aviv, Israel have
successfully 3D printed a human heart.
• It was the first time a fully-
vascularized human heart was
entirely 3D printed using human
cells.
• The human cells were taken from
the test subject’s fatty tissue and
reformed to become stem cells.
• These new “cardiac” cells were
mixed with inorganic materials to
make bioinks that were finally 3D
printed.
44. 3D PRINTED STEAK:
• Redefine meat is a company with a
mission to 3D print Beef.
• Their patent pending process can
create this meat with the same
texture , flavor and appearance
from natural ingredients.
• They have a 95% smaller
environmental impact, no
cholesterol and is more
affordable.
• They will soon be creating other
kinds of plant based meats with
beef being the first.
45. 3D PRINTED KFC NUGGETS:
• KFC in Russia has collaborated with
a local bioprinting company called
3D Bioprinting Solutions.
• They are now exploring ways on
how they can do it on an
industrial scale for a chain like
KFC.
• KFC is exploring the possibility to
replace and reduce the expense
of raising animals for meat.
• They are going to be a pioneer for
3D printed meat in their sector.
48. CONCLUDING THOUGHTS:
• 3D Printing has been rapidly developing in terms of speed, materials and
applications.
• Due to the versatility of the technology it is applicable to almost all industrial
sectors.
• We are far away from a time where additive manufacturing replaces
traditional manufacturing since they both have their own individual pros and
cons.
• Through innovation in design for additive manufacturing, we will be able to
utilize the technology to its true capabilities.
• 3D printing in the medical sector could someday print organs on demand
which would increase the overall life expectancy of our civilization.