Additive Manufacturing in Industry
Definition
Additive Manufacturing
Additive manufacturing involves techniques that build objects by adding material layer by layer.
Key Additive Manufacturing Techniques
- Powder Bed Fusion (PBF)
- Material Extrusion
- Selective Laser Sintering (SLS)
Powder Bed Fusion (PBF)
Definition
Powder Based Fusion (PBF)
It is an additive manufacturing technique that uses directed thermal energy to fuse layers of powdered material, forming a 3D object.
- Process: A laser or electron beam selectively melts powder in a thin layer.
- Materials: Metal or polymer powders (e.g. titanium, nylon)
- Applications: Aerospace brackets, implants, high-strength parts
- Example methods: Selective Laser Melting (SLM), Electron Beam Melting (EBM)
Note
PBF allows for the creation of intricate geometries and internal structures that are difficult or impossible to achieve with traditional methods.
Material Extrusion
Definition
Material Extrusion
The process of forming a material by forcing it through a die, resulting in objects with a fixed cross-section
Note
- In the context of 3D printing, material extrusion refers to Fused Deposition Modelling (FDM) or Fused Filament Fabrication (FFF).
- A 3D printing process where a thermoplastic filament is heated and extruded through a nozzle to build up parts layer by layer.
- Process: Thermoplastic filament is heated and extruded through a nozzle to build objects layer by layer.
- Materials: PLA, ABS, PETG
- Applications: Rapid tooling, jigs, low-strength consumer parts
- Strengths: Cheap, simple, accessible
Selective Laser Sintering (SLS)
Definition
Selective Laser Sintering (SLS)
SLS is an additive manufacturing technique that uses a laser to fuse small particles of material into a solid 3D shape for rapid prototyping.
- Process: A laser sinters powdered polymer (usually nylon), bonding the material without fully melting it.
- Materials: Nylon, TPU
- Applications: Functional prototypes, small batch production
- Strengths: No support structures needed; strong, complex parts
Advantages of Additive Manufacturing in Industry
- Design Flexibility - enables the creation of complex geometries, including internal structures and lattice designs, that are difficult to achieve with traditional methods.
- Material Efficiency - by adding material only where needed, AM reduces waste and optimises resource use.
- Customisation - it allows for the production of customised parts without the need for retooling, making it ideal for low-volume and bespoke manufacturing.
- Rapid Prototyping - can quickly iterate and test prototypes, accelerating the product development cycle.
Challenges and Considerations
- Material Limitations - not all materials are suitable for AM, and some may require post-processing to achieve desired properties.
- Surface Finish - parts may have rough surfaces that require additional finishing processes.
- Cost - while AM is cost-effective for low-volume production, it may not be competitive with traditional methods for high-volume manufacturing.
