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Additive manufacturing

What is additive manufacturing? in simple terms additive manafacturing is when you create a product or component using the process of layer by layer printing. The materials can be plastics or metals depending on the printer.

Why don't we use subtractive for everything?

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why additive?

Prototyping is perfect for additive you can create a prototype and print it within days

Cost efficent in small batches

Small parts are better printed instead of cutting it in a large block of material

They are almost autonomous, once set up and going it will not need constant care and can be left to print until finnished.

additive manufActuring

powder bed fusion

powder bed fusion

Selective Laser Sintering (SLS)

Selective Heat Sintering (SHS),

Selective laser sintering (SLS) is a 3d printing process (additive manufacturing) that uses high-powered lasers to sinter, or bind, finely powdered material together into a solid structure. They both use the same process.

How does Selective Heat Sintering work? the printer uses a powder In SHS manufacturing, powdered material is heated to just below its melting point and then spread out into an even layer over the building platform using a roller. A thermal print head moves across the platform and melts a cross section of the CAD model in the powder, which causes the powder particles to adhere to each other by sintering. The building platform is then lowered down corresponding to a layer thickness. The process is repeated until the model is completed.

Whats the difference ?

advantage and disadvantages of powder bed fusion

disadvantage

advantage

Material Waste is Reduced: After the item is completed, the surplus powder is collected and recycled. This reduces the amount of waste created by subtractive manufacturing methods. Allows for rapid design iteration, allowing engineers to update CAD designs and replicate damaged parts, culminating in the creation of new products. Because it saves manufacturing times, PBF is the preferred material for complicated items with delicate interior geometry. When compared to other technologies such as metal casting or MIM, a whole item can be conceived, manufactured, tested, redesigned, and printed in less time. PBF can work with a wide range of materials, including titanium, tool steel, Inconel®, aluminium, stainless steel, and others that can be powdered using gas or plasma atomization processes.

Powder bed fusion is one of the slowest additive manufacturing techniques because to the time required for powder preheating, vacuum creation, and cooling-off. Weak Structural Qualities: Because powder bed fusion items are manufactured in layers, their structural properties are not as robust as those produced using other manufacturing techniques. Surface Texture: The surface quality of powder bed fusion components is determined by the grain size of the powder, which may resemble production techniques such as sand casting and die casting. the need of inert gases to work correctly. the metal the is used will not want to be oxidised which will mean it will need to eb in a controlled chamber which could be a entire different machine increasing prices and set up time.

PRESENTATION

vat Photopolymerization

VAT Photopolymerization

advantage 3

advantage 2

advantage 1

Photopolymerization printers frequently have far superior detail to extrusion printers at the expense of durability. And resistance instead the quality and complexity of the design.

In contrast to an extrusion printer, the works of a VP printer moves vertically away from the vat. Slowly going up after each layer.

Vat Photopolymerization is the process of curing (solidifying) a liquid polymer or resin layer by layer to generate a solid item. To eventually create a product or component.

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ultra violet resin printing

resin printing

this process is mostly known as resin printing, it uses a liquid resin and uv light to create different layers that then stack onto each other to create a 3d object. each layer is formed together with the uv light that is shined over the areas that are going to be formed. this then is repeated every layer while the bed is slowly risen to create space for another layer. this is the opposite of a extrusion printer as the print is created upside down and is created using resin. this version of process is less commonly known as digital light processing(DLP)

what is the difference between vat Photopolymerization and powder bed fusion

the main difference between the 2 is the types of material used, vp (vat Photopolymerization) uses a polymer resin compared to the usual metals that powder bed fusion

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vp can have very high qualitys and can create some of the cleanest prints possible however the pdf can create large metal prints

bed fusion makes prints out of reusable metal powder which is cleaned up perfectly to create a sand blasted type prints that can be used instantly after extraction.

safety with additive processes

the boring bit

depending on the process depend on the safety issues and procedures. ultra violet is a dangerous ray in the light spectrum, it can create hazardous enviroments so when working with the printer it is best to use protective films that block out the light and helps protect the users. unless you want a great tan with the possability of some skin condition for long duration of time it is best if you use the protection that is normally provided with the printers

there are a few hazards with powder bed fusion the main 2 are heat and lasers(if it uses lasers in the process) heat can cause multiple different burns and damage and the lasers can instantly damage and destroy things that is not intended to be heated. powder can also be a hazard depending on how it is desposed and worked around if the powder becomes airbourne it can become hazardous

what have we learnt?

additive process are awsome!

they save alot of waste and can be the future

the use of alot of proceses can create multiple types of designs that can be almost impossible on a regular milling process

all additive processes use the same type of layer by layer forming

additive can help increase the amount of products in the world with the speed of prototyping

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whats the difference?

the difference between the 2 types of powder bed fusion is the heating method SHS uses preheated powder that is just bellow the melting point and then uses a hot head to heat the areas needed to create the end object SLS uses a laser to melt the layer and create the object. these are just 2 examples of powder bed fusion there are many more that use a very similar process

the end print needs to be cleaned after it is printed. the print is slow to construct. it is expensive. the print bed is much smaller than extrusion printing. the bed needs to be perfectly parallel compared to the printing light

subtractive manufacturing

waste is one of the largest factors of this type of subtractive manufacturing which can make it expensive this can also be slow and it is not the best process to use for small batches of product becasue of the expensive set up and running costs

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