AM Process Overview

AM Process Overview

Index

Introduction

Direct Energy Deposition

AM Quiz

Key Takeaways

What's next? Upcoming sessions overview

Introduction

Additive Manufacturing (AM) is a process that builds objects layer by layer from digital designs, using materials like polymers and metals. Unlike traditional methods, it reduces waste and enables complex geometries. AM is widely used in aerospace, automotive, and healthcare for rapid prototyping and custom production. It enhances efficiency, sustainability, and design flexibility.

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Additive vs. Traditional Manufacturing

A side-by-Side View

General Principles Terminology

Reference to ISO/ASTM 52900:2015(E)

ISO/ASTM 52900:2015(E) provides a unified terminology framework for Additive Manufacturing (AM), ensuring clarity and consistency across industries. It defines key terms, processes, and classifications, helping manufacturers, researchers, and engineers communicate effectively. This standard categorises AM processes, such as material extrusion, powder bed fusion, and vat photopolymerisation, establishing a foundation for quality control, regulatory compliance, and innovation in the field.

Additive Manufacturing (AM) is defined as: "A process of joining materials to make parts from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies." Main Role of Additive Manufacturing: Massify customization instead of massify production!

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The 7 Families of AM

Classification of Additive Manufacturing Processes According to ISO/ASTM 52900

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02

Direct Energy DEPOSITION (ded)

DED - Metal AM

Directed Energy Deposition (DED) uses a focused energy source, like a laser or electron beam, to melt and deposit material, creating strong, high-precision metal parts

Process Definition

“Additive Manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited" Source: ISO 17296 2, Additive manufacturing General principles Part2:Overview of process categories and feedstock

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Direct Energy Deposition

Wire and Wire and Electron Beam Additive Manufacturing (DED WEB)

Applications and sectors

Materials

Feedstock Form and Build Volume

Advantages and Limitations

AM Quiz: Are You Layering Up the Knowledge?

Key Takeaways

Material & Process Versatility

Design Freedom & Customisation

Efficiency & Waste Reduction

Future of Manufacturing

What's Next? Upcoming Session Overview

Binder Jetting

Powder Bed Fusion

Material Extrusion

Vat Photopolymerization

Sheet lamination

Material Jetting

Questions?

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With ongoing advancements, AM is set to revolutionise industries by reducing costs, improving production speed, and enabling on-demand manufacturing.

Materials Steel , 4340 Stainless Steel Titanium and Titanium alloys , Ti64 Aluminum , 2319, 4043

Tantalum Tungsten Niobium Inconel 718, 625

From metals to polymers, AM supports a wide range of materials and multiple process families tailored to specific applications.

Illustration of the Directed Energy Deposition (DED) Process

"The deposition head defines the thermal energy source: laser beam, electron beam, or electric arc. The raw material can be a wire or a powder. A shielding gas atmosphere protects the melt pool. In electron beam-based DED, a high vacuum chamber is required. TIG, tungsten inert gas; GMAW, gas metal arc welding." (1)

AM builds objects layer by layer, minimising material waste and enabling sustainable manufacturing.

Turbine Blades for Energy Production Nuclear Components Refractory Metal Components Ballistic Materials Medical Equipment Industrial Pump Components Semiconductor Manufacturing Equipment Tooling Repair and Reconditioning

Souce: https :://www lboro ac uk/research/amrg/about/the 7 categoriesofadditivemanufacturing/directedenergydeposition/

Feedstock Form: Wire Wire feedstock in Directed Energy Deposition (DED) provides high material efficiency and strong metallurgical bonding, making it ideal for repairing and manufacturing large metal components.

Additive Manufacturing Workflow

This image illustrates the Additive Manufacturing (AM) workflow, specifically using Powder Bed Fusion technology. The process starts with a digital 3D model, which is then sliced into layers. The printer builds the object layer by layer by selectively fusing powder material, resulting in the final complex structure with high precision and intricate geometries.

Credits: EOS

AM in Everyday Life...

Examples of how AM is used in industries like healthcare (prosthetics), aerospace (lightweight components), and fashion (custom accessories)

Complex geometries and tailor-made solutions are possible, offering advantages in aerospace, healthcare, and industry.

Advantages Higher deposition rate Large pieces (larger manufacturing space) High value metals (low waste) Reactive metals (Ti, Al, TiAl) Wire material (+ cheap, flammable )

Limitations Big and complex equipment High investment and maintenance costs High cost Vacuum chamber needed (+time, access)