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.
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 DfAM 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 IoT Medical Devices 343 K. Vijetha, Uzwalkiran Rokkala and Lingaraju Dumpala 19.1 Introduction 343 19.2 Additive Manufacturing 345 19.3 Future Scope for IoT 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 PolyJet 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
Sandip Kunar, PhD, 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, PhD, 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, PhD, 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, PhD, 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, PhD, 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.
