Technological progress also finds expression in Additive Manufacturing. 3D printing, as this process is also known as, offers many advantages for different areas and industries: from medicine to the fashion and automotive industries or aerospace. Find out In this blog post, what additive manufacturing is, how it works, in which areas of application it is used, what the advantages are and much more.
Additive Manufacturing Meaning
Additive Manufacturing (AM), also colloquially known as 3D printing, is a term that is primarily used in the industry. It includes a series of Additive Manufacturing processes for creating three-dimensional objects that are built layer by layer (layer construction principle).
From the design to the finished object, several work steps are necessary, which are divided into three main processes. These are closely coordinated with one another in order to be able to meet specific manufacturing requirements. Therefore, post-processing is only omitted in exceptional cases.
- Pre-process: Before the object can be manufactured, the data and the system must first be prepared.
- In-process: After the preparations, the actual 3D printing process is carried out and the object is created.
- Post-process: Finally, the surface of the object is reworked by, among other things, removing supporting structures. The more demanding the subsequent production application will be, the more post-treatment time and steps will be required.
Additive Manufacturing Functionality
Although additive processes exist with which objects can be created directly in all 3 construction directions, they are usually done layer by layer. After the first layer has been created, further levels are stacked in a third spatial direction, creating three-dimensionality. The material connection is achieved by melting or hardening through chemical processes.
The basis for this process lies in digital 3D design data (CAD files), which are converted and processed using special software for 3D printers, so that extremely precise production is possible. In addition, the data and thus the planned property can be adapted to suit demand, so that a high level of flexibility is possible.
Additive Manufacturing Applications
Additive Manufacturing processes have already been established and used successfully in some industries due to their advantages over conventional processes. The materials can be metals, plastics, synthetic resins, ceramics, glass, sand, wood or even concrete.
The selection of the process and the 3D printer depends on the goals and requirements for production. Examples would be: different wall thicknesses, shapes in small sizes, internal structures, undercuts or the modeling of three-shape surfaces.
Additive Manufacturing applications can be found particularly in areas in which attention to detail, complex geometries and a high degree of individualization are in the foreground. This is particularly the case in medical and dental technology (prosthetics), but also in the fashion world, in tool and mechanical engineering (prototype construction), in the automotive industry or aerospace.
Advantages of Additive Manufacturing
Compared to traditional methods, there are significant advantages of Additive Manufacturing processes in terms of:
- High precision and individualization
The production of complex structures with high stability, lightness and quality is given, as is flexibility in terms of individualization.
- Cost efficiency and time savings
Better cost-effectiveness is achieved because workpieces that previously had to be assembled from several individual pieces can be created in one piece. This reduces manual work, which also minimizes manufacturing costs.
- Size of production location
The use of 3D printers require less space, e.g. because large, heavy machines or tools for casting molds are not needed
- Flexibility
Additive Manufacturing processes also work via a digital interface, which means they can be used decentrally and geographically independent of the production location (Cloud production).
- Environmental friendliness
A more sustainable solution with 3D printing includes better energy efficiency, fewer transport routes and material waste or rather material requirements.
Additive Manufacturing Processes
There are a number of different Additive Manufacturing Processes that process different materials and can be used according to individual requirements. The two most important process groups are metal printing and plastic printing, which in turn include some subgroups for special applications. You will then find an overview of the most important procedures with a brief explanation:
Powder Bed Fusion
With Powder Bed Fusion (PBF), powder is melted using a laser (SLM) or electron beam (EBM). We use laser beam melting in our 3D metal printers 2Create and 2Create Plus.
Binder Jetting
With Binder Jetting, a powdery base material is bonded in places with a liquid binder, thereby building up layers of the object. The starting materials include: metal, plastic, plaster or sand.
Material Jetting
During Material Jetting, liquid material (resin axis or thermoplastics) is applied dropwise and selectively to a printing plate and solidified with UV light. Examples: Poly-Jet Modeling (PJM), Multi-Jet Modeling (MJM).
Material Extrusion
Material is heated and liquefied during Material Extrusion. The liquid material is then applied in layers through a gland and onto the base. A permanent connection is then created through cooling. A well-known process for plastic/metal/composite filament is the Fused Layer Modeling (FLM).
Vat Photopolymerization
In VPP process, liquid plastics are hardened layer by layer using UV light. In contrast to the jetting process, the material is not applied to a construction platform, but is already in a basin. The platform is immersed in the plastic basin. Examples: Stereolithography (SLA), Digital Light Processing (DLP).
Sheet Lamination
In Sheet Lamination, thin “film layers” are placed on top of each other and connected to each other. Materials such as paper, plastics or metals are glued or welded together. Ultrasonic vibrations (Ultrasonic Additive Manufacturing; abbr. UAM) are also used for metal.
Directed Energy Deposition (DED)
The DED process is often used in combination with metals in the form of powder or wire for surface refinement or to repair and modify existing components. Depending on the method, a laser, an electric beam or a plasma source is used.
Additive Manufacturing Materials
The choice of process and 3D printer is influenced by the specific requirements and goals as well as the materials used. Fort the industry approximately 4 main groups can be categorized, some examples below:
- 1. Metals: titanium, steel, aluminum, copper, nickel
- 2. Plastics (polymers): ABS, PETG, PET, PLA
- 3. Ceramics: aluminum oxide, zirconium dioxide, silicas
- 4. Biomaterials: gelatin, collagen, cellulose
The materials can still be distinguished from each other according to their material properties, so they are used as powder, granules, filament, wire or as liquid.
Conclusion – Additive Manufacturing
Additive Manufacturing (3D printing) includes Additive Manufacturing Processes that are based on the layer construction principle and offer significant advantages over conventional methods.
Traditional subtraction methods require more work, materials and time because processes are less automated. Furthermore, there is a greater need for manual manufacturing, materials, tools and possibly heavy machinery for casting, which requires a larger production facility and personnel. These requirements cause manufacturing costs to rise.
In comparison, the advantages of Additive Manufacturing lie in the automation and leaner process flows. Added to this is the lower material requirement, labor, time and cost expenditure, as well as possibilities that cannot be achieved in this way with conventional methods. These include: the creation of complex geometries, a high level of precision and a high degree of individualization.
Today, Additive Manufacturing has already established itself in many areas due to these advantages. Additive Manufacturing processes are used in medicine, fashion, the automotive industry, construction and aerospace and also offer potential to be further developed and used in other industries in the future.
FAQ: Additive Manufacturing
What is Additive Manufacturing?
Additive Manufacturing includes additive manufacturing processes that build three-dimensional objects from specific materials layer by layer. The model is based on the information in the CAD file, which provides information for the 3D printers via special software.
In which areas of application is Additive Manufacturing used?
The application of Additive Manufacturing processes extends across various sectors, such as medical and dental technology (prosthetics), toolmaking and mechanical engineering (prototypes) as well as the automotive and aerospace industries.
The technology creates significant added value, particularly for areas and companies for which a high degree of individualization, complex design and cost efficiency are important. Example: The dental industry with the need for individualization for dental implants or crowns.
What are the advantages of Additive Manufacturig?
The advantages of Additive Manufacturing compared to traditional processes are: Higher precision and personalization with high quality, production of very complex geometries, cost and time savings as well as less Co-2 emissions and material waste. Due to its digital interface, it is also characterized by decentralization, independence from the production facility and a smaller production location.
What Additive Manufacturing processes are there?
There are a total of 11 Additive Manufacturing processes that are used according to specific requirements and materials. The 7 most famous include: Binder Jetting, Material Jetting, Material Extrusion, Vat Photopolymerization, Powder Bed Fusion, Sheet Lamination and Directed Energy Deposition (DED).
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Author: Markus Wolf
Passionate about 3D printing, while being
CTO and Co-Founder of 2oneLab.
