This volume focuses on the fundamentals of additive manufacturing and its components, explains why and what we do, outlines what is crucial to the user, offers details on important applications such as in the aerospace, automotive, or medical areas, and the difficult certification process.
This book explores the advancements in additive manufacturing which produces solid, free-form, nearly net-shaped objects. This refers to items that are easy to use, out-of-the-box, and not bound by the design constraints of modern manufacturing techniques. AM expands the definition of 3D printing to encompass a variety of procedures that begin with a three-dimensional computer model, incorporate an AM production procedure, and result in a useful product. The AM process can be confusing due to the rapid rise of competing techniques for fabricating 3D parts. This volume provides a thorough review of the basic components and procedures involved in additive manufacturing. It outlines a road map for where to begin, what to study, how everything goes together, and how AM might enable ideas outside traditional processing to realize those ideas in AM. Furthermore, this book investigates the benefits of AM including affordable access to 3D solid modeling software. With this software, learning is achieved without having to invest in costly industrial equipment.
AM encompasses a variety of techniques, including those that use high-intensity beams to fuse powder or wire, and hybrid techniques that combine additive and subtractive manufacturing techniques. AM-related processes have developed at breakneck speed, giving rise to a deluge of acronyms and terminology, not to mention the emergence, acquisition, and demise of new businesses. By combining ideas and aspirations, better methods will be revealed that result in useful products that will serve and contribute to a lasting future.
Although expensive commercial additive manufacturing equipment can cost hundreds of thousands to millions of dollars, a lack of access to equipment does not preclude the study of the technology. 3D printing services will undoubtedly become more reasonable for small- and medium-sized organizations as their prices decline. Hybrid 3D plastic printing technologies and low-cost hobbyist 3D weld deposition systems are already in development which will make the best 3D printers accessible and affordable. This book will assist the reader in determining what is required to begin, which software, supplies, and procedures best suit, and where to obtain additional information.
Audience
The book will be used by engineers and R&D researchers involved in advanced additive manufacturing technology, postgraduate students in various disciplines such as mechanical, manufacturing, biomedical, and industrial engineering, etc. It will also serve as a reference manual for manufacturing and materials engineers involved in additive manufacturing and product development.
Cuprins
Preface xix
Acknowledgment xxiii
1 Fundamentals and Applications of Additive Manufacturing 1
Sandip Kunar, Jagadeesha T., Gurudas Mandal, Akhilesh Kumar Singh and S. Rama Sree
1.1 Basics and Definitions 1
1.2 Application Levels 4
1.3 Application Levels – Indirect Processes 9
1.4 Machines for Additive Manufacturing 13
1.5 Conclusions 13
2 Characteristics of Additive Manufacturing Process 15
Sandip Kunar, Jagadeesha T., Gurudas Mandal, Akhilesh Kumar Singh, Rajesh Kumar, Aezeden Mohamed and Param Singh
2.1 Basic Principles 15
2.2 Generation of Layer Information 17
2.3 Physical Principles for Layer Formation 22
2.4 Summary Evaluation of Rapid Prototyping Methods 33
2.5 Conclusion 36
3 Directed Energy Deposition (DED) Process 39
M. Sivakumar, N.S. Balaji, G. Rajesh Kannan and R. Karthikeyan
3.1 Introduction 39
3.2 Direct Energy Deposition (DED) 40
3.3 Materials Used in the DED Process 48
3.4 Hybrid DED Process 50
3.5 In Situ Monitoring in DED 51
3.6 Case Studies 52
3.7 Limitations and Challenges 54
3.8 Applications of DED Process 55
4 Current Progress and Future Perspectives of Biomaterials in 3D Bioprinting 61
Prerona Saha, Ankita Nandi, Jaideep Adhikari, Abhishek Ghosh, Asiful H. Seikh and Manojit Ghosh
4.1 Introduction 61
4.2 Biomaterials Used in Designing a Bioink 64
4.3 Growth Factors Used in Bioink 72
4.4 Bioimaging of Bioink 72
4.5 Extracellular Vesicle Loaded Bioink 72
4.6 Requirements for Ideal 3D Bioprinting Materials 73
4.7 3D Bioprinting Technologies 75
4.8 Challenges Faced by 3D Bioprinting Techniques 82
4.9 Conclusion 82
5 Powder Bed Fusion Process – State of Art 89
G. Rajesh Kannan, M. Sivakumar, B. Jagadeesh and N. S. Balaji
5.1 Introduction 89
5.2 Powder Bed Fusion (PBF) 90
5.3 Laser Powder Bed Fusion (L-PBF) 94
5.4 The Influence of L-PBF Processing Parameters on the Microstructure 100
5.5 Merits and Demerits of Powder Bed Fusion Process 102
5.6 Applications of Powder Bed Fusion Process 104
5.7 Summary 104
6 Cobalt-Chromium Alloy Additive Manufacturing Technologies for Biomedical Applications 109
Pravin Pawar, Amaresh Kumar and Raj Ballav
6.1 Introduction 109
6.2 Selective Laser Melting (SLM) Additive Manufacturing 111
6.3 Laser Powder-Bed-Fusion (LPBF) Additive Manufacturing 113
6.4 Direct-Metal Laser-Sintering (DMLS) Additive Manufacturing 114
6.5 Selective Laser Sintering (SLS) Additive Manufacturing 114
6.6 Laser Melting (LM) Additive Manufacturing 115
6.7 Electron Beam Melting (EBM) Additive Manufacturing 115
6.8 Micro-Plasma Based Additive Manufacturing (MPBAM) 115
6.9 Direct Metal Fabrication (DMF) Additive Manufacturing 115
6.10 Wire and Arc Additive Manufacturing (WAAM) 115
6.11 Summary of Additive Manufacturing Technologies of Cobalt-Chromium Alloy Material for Bio-Medical Applications 116
6.12 Conclusion 117
7 Cold Spray Additive Manufacturing: Principles, Applications, and Recent Advancements 121
Jagadeesha T. and Sandip Kunar
7.1 Introduction 121
7.2 Literature Review 123
7.3 Phenomena and Factors Behind CSAM 126
7.4 Numerical Simulation of CSAM 126
8 Integrating Metal Forming and Additive Manufacturing for Enhanced Product Quality and Efficiency 129
Jagadeesha T. and Sandip Kunar
8.1 Introduction 130
8.2 Need of Additives in Metal Forming Process 130
8.3 Erichsen Test 131
8.4 Types of Additives 132
8.5 Effects of Additives in Various Processes 134
8.6 Traditional Sheet Metal Forming and Additive Manufacturing 136
8.7 Technologies Used in Metal Forming That Involves Additives 137
8.8 General Impacts of Additives in Additive Manufacturing 138
8.9 Factors Affecting Additive Manufacturing 140
8.10 Conclusion 141
9 Impacts of Additives on Failure Issues Linked with Additively Manufactured Products 145
Jagadeesha T. and Sandip Kunar
9.1 Introduction 145
9.2 Additive Manufacturing 146
9.3 Technological Aspects 148
9.4 Challenges in Additive Manufacturing 152
9.5 Limitations and Future Scope 154
9.6 Conclusion 155
10 Nano-Additives for Advanced Additive Manufacturing: Enhancing Quality, Sustainability and Performance 157
Jagadeesha T. and Sandip Kunar
10.1 Introduction 157
10.2 Application of Nano-Additives 158
10.3 Literature Survey 159
10.4 Methodology 160
10.5 LAM of the Titanium Carbide Nanoparticles Strengthened by Nickel Based Nano-Size Composites 162
10.6 Role of Nano-Additives to Enhance the Fuel Properties of Tyre Oil for Green Environment 162
10.7 Conclusion 163
11 Processing of Biomaterials by Additive Manufacturing 165
R. Prayer Riju, S. Arulvel, D. Dsilva Winfred Rufuss, Jayakrishna Kandasamy and P. Jeyapandiarajan
11.1 Introduction 165
11.2 Diverse Additive Manufacturing Techniques for Processing Biomaterials 166
11.3 Conclusion 183
12 Safety and Environmental Protection in Additive Manufacturing 187
N.S. Balaji, M. Sivakumar, G. Rajesh Kannan and R. Karthikeyan
12.1 Introduction 187
12.2 Environmental Impacts of Additive Manufacturing 189
12.3 Additive Manufacturing: A Sustainable Approach to Reducing Environmental Degradation 190
12.4 Developing a Sustainable Additive Manufacturing Ecosystem: Basic Building Blocks 192
12.5 Enriching Sustainability Through Additive Manufacturing Processes: A Sequential Overview 194
12.6 AM Security and Safety: A Comprehensive Approach 195
12.7 Summary 198
13 Advanced Developments in Additive Manufacturing of Silicone Rubber Elastomers 203
Mohammad Bagher Jafari, Hossein Doostmohammadi, Mostafa Baghani and Majid Baniassadi
13.1 Introduction 203
13.2 Chemical Structure and Properties of Silicone Rubbers 204
13.3 Additive Manufacturing Techniques for Fabrication of Silicone Rubber Structures 205
13.4 3D Printable Silicone-Based Materials 205
13.5 Progress and Applications Proposed for 3D Printed Silicone Rubbers 207
13.6 Challenges and Future Research Direction 212
13.7 Conclusion 213
14 Laser-Assisted Additive Manufacturing Techniques for Advanced Composites 217
Nitai Chandra Adak, Fahim Sharia and Wonoh Lee
14.1 Introduction 217
14.2 Classification of Laser-Based Additive Micromanufacturing Techniques 218
14.3 Challenges in Laser-Based Additive Manufacturing of Composites 231
14.4 Conclusions and Future Research Opportunities 232
15 Stereolithography-Based Polymer Additive Manufacturing Process for Microfluidics Devices: A Review 237
Ajit Biswas, Amit Kumar Singh and Debasree Das
15.1 Introduction 237
15.2 Polymer Additive Manufacturing Processes 242
15.3 Stereolithography (SLA) for Microfluidics 246
15.4 Applications of Polymer Additive Manufacturing in Microfluidics 250
15.5 Challenges and Future Prospects of Polymer Additive Manufacturing Processes in Microfluidics 255
15.6 Conclusion 256
16 Biomaterials and Bioinks: A Synergistic Approach to Bioprinting 269
M. Abdur Rahman, G. Rajesh and N. Sri Rangarajalu
16.1 Introduction 270
16.2 Bioprinting 273
16.3 Extrusion-Based Bioprinting 276
16.4 Inkjet-Based Bioprinting 279
16.5 Significant Aspects of Bioprinting 280
17 Significance of Additive Manufacturing in Aerospace and Automotive Industries 293
M. Abdur Rahman, Ravi Kumar S. and A.S. Selvakumar
17.1 Introduction to Additive Manufacturing (AM) in the Aerospace and Automotive Industry 294
17.2 AM Processes in the Aerospace Industry 296
17.3 AM Processes in the Automotive Industry 296
17.4 AM Applications of Automotive and Aerospace Industries 297
17.5 Material Selection in AM 298
17.6 Df AM in Aerospace Applications and Automotive Applications 299
17.7 Supply Chain and Manufacturing Integration in the Aerospace Industry 300
17.8 Supply Chain and Manufacturing Integration in the Automotive Industry 301
17.9 Maintenance, Repair, and Overhaul (MRO) in Aerospace AM 301
17.10 Maintenance, Repair, and Overhaul (MRO) in Automotive AM 302
17.11 Circular Economy in the Aerospace Industry 307
17.12 Circular Economy in the Automotive Industry 307
17.13 Conclusion 309
17.14 Future Scope 310
18 Sustainability and Efficiency: The Green Potential of Additive Manufacturing 317
M. Abdur Rahman, Serajul Haque, N. Sri Rangarajalu and D. R. Rajendran
18.1 Introduction to Additive Manufacturing (AM) and Its Role in Sustainability 318
18.2 The Relevance of AM in the Context of Sustainability and Efficiency 319
18.3 Life Cycle Assessment (LCA) of AM Processes and Products 323
18.4 Identification of Key Environmental Hotspots in AM Technology 324
18.5 Sustainable Materials and Additive Manufacturing 325
18.6 Biodegradable and Recycled Materials in AM 327
18.7 The Potential for Renewable Energy Integration in AM Processes 328
18.8 Waste Reduction and Circular Economy in Additive Manufacturing 329
18.9 Research and Development Areas to Enhance AM’s Green Potential 333
18.10 Conclusion 335
19 Role of Additive Manufacturing in Io T Medical Devices 343
K. Vijetha, Uzwalkiran Rokkala and Lingaraju Dumpala
19.1 Introduction 343
19.2 Additive Manufacturing 345
19.3 Future Scope for Io T 349
19.4 Conclusions 350
20 Additive Manufacturing of Superhydrophobic Architectures 353
Hossein Doostmohammadi, Majid Baniassadi and Mostafa Baghani
20.1 Introduction 353
20.2 Principles of Superhydrophobicity of Structures 354
20.3 Additive Manufacturing Techniques and Methods for Creation of Superhydrophobic Surfaces 356
20.4 Advantages and Disadvantages of 3D Printing Techniques 367
20.5 Conclusion, Challenges, and Future Outlook 368
21 Fiber-Reinforced Composite and Topology Optimization in Additive Manufacturing 373
Tien-Dat Hoang and Van Du Nguyen
21.1 Introduction 373
21.2 Printed Model Without Fiber Reinforcement 376
21.3 Printed Model with Continuous Fiber Reinforcement 380
21.4 Printing Model Integrating Topology Optimization and Continuous Fiber Reinforcement 383
21.5 Conclusion 385
22 Comparative Analysis of Mechanical Characteristics in Additive Manufacturing on Polylactic Acid and Acrylonitrile Butadiene Styrene Materials 389
Kaustubh Pravin Joshi and Anil Dube
22.1 Introduction 389
22.2 Literature Review 390
22.3 Experimental Setup 392
22.4 Results and Discussion 396
22.5 Conclusion 402
23 A Comprehensive Review on Polymers and Metal Additive Manufacturing 405
Praveena B. A., Santhosh N. and Anand G.
23.1 Introduction 406
23.2 Additive Manufacturing Processes and Methods 409
23.3 Materials for Additive Manufacturing 410
23.4 Additive Manufacturing Applications 412
23.5 Challenges and Limitations 414
23.6 Future Directions and Opportunities 415
23.7 Conclusion 417
24 Sub-Zero Additive Manufacturing: A Green Solution to Pattern Making in the Investment Casting Industry 419
Pushkar Kamble, K. P. Karunakaran and Yicha Zhang
24.1 Introduction 419
24.2 Process of Using Ice Patterns by Sub-Zero Additive Manufacturing 421
24.3 Economic Comparison 424
24.4 Conclusions 425
24.5 Future Scope 425
25 Effect of Orientation on the Tensile Strength of 3D Printed Rectangular Solid Bars 427
Neel Kamal Gupta and Pawan Kumar Rakesh
25.1 Introduction 427
25.2 Modelling and Simulation 429
25.3 Manufacturing of Rectangular Solid Bar by Poly Jet Printing Technology 433
25.4 Design of Experiment 436
25.5 Selection of Process Parameters 436
25.6 Selection of Orthogonal Array 438
25.7 Conclusion and Future Scope 440
26 Advanced Techniques in Wire Arc Additive Manufacturing: Monitoring, Control, and Automation 443
M. Sivakumar, R. Karthikeyan, N.S. Balaji and G. Rajesh Kannan
26.1 Introduction 443
26.2 Wire Arc Additive Manufacturing 444
26.3 Defects in the WAAM Process 447
26.4 Sensing Technology in Additive Manufacturing and Challenges in WAAM 448
26.5 Quality Control Strategies for WAAM 455
26.6 Automation in Wire Arc Additive Manufacturing 457
26.7 Case Study: Implementing a Closed-Loop Multiple Sensors System for Quality Control in the WAAM Process 459
27 Vat Photopolymerization 467
J. Suresh Kumar, Akshaya Senthilkumar, S. Naveen Rajkumar and K. Kalaichelvan
27.1 Introduction 467
27.2 Vat Polymerization Process 468
27.3 Vat Polymerization Techniques 470
27.4 Photoinitiator Materials 477
27.5 Applications 479
References 480
Index 483
Despre autor
Sandip Kunar, Ph D, is an assistant professor in the Department of Mechanical Engineering, Aditya Engineering College, A.P., India. He has published more than 50 research papers in various reputed international journals, national and international conference proceedings, 16 book chapters, and 9 books as well as two patents. His research interests include non-conventional machining processes, micromachining processes, advanced manufacturing technology, and industrial engineering.
Jagadeesha T, Ph D, is an associate professor in the Department of Mechanical Engineering, National Institute of Technology Calicut, India. He has 25 years of industry and academic experience and has authored mechanical engineering workbooks and textbooks and published more than 75 papers in international and national journals/conferences. As well as four patents. His research interests are advanced machining, additive manufacturing, fluid power control, advanced materials, vibration and noise control, and FEM.
S. Rama Sree, Ph D, is a professor in the Computer Science and Engineering Department, Aditya Engineering College, India. She has published more than 50 papers in international/national journals and conferences, four patents, and co-authored on data structures. Her research interests include software, soft computing, applications of machine learning techniques, medical diagnosis and cloud computing.
K. V. S. R. Murthy, Ph D, is a professor in the Electrical and Electronics Engineering Department, Aditya Engineering College, India. He is an expert in power system operation and control, and the application of artificial intelligence techniques in power distribution systems. He has published 35 research papers in various journals/conferences.
M. Sreenivasa Reddy, Ph D, is the Director of Aditya Group of Educational Institutions and Principal of Aditya Engineering College, India. He has more than 25 years of industry and academic experience and is an expert in additive manufacturing technology. He has 11 patents granted and published many journal articles and book chapters.
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