Additive Manufacturing at Micro Level : Some Challenges
P. V. Madhusudhan Rao IIT Delhi (
[email protected])
TEQIP Workshop on Advanced Micro-Nano Technologies IIT Kanpur May 11, 2016
What is Additive Manufacturing ? Additive Manufacturing refers to a class of manufacturing methods which quickly produce physical prototypes from 3D CAD data
CAD Model
Prototype from Additive Manufacturing
(Also known as rapid prototyping, Additive Manufacturing or layered manufacturing)
Additive Manufacturing
Manufacturing through layer by layer addition
Additive Manufacturing Equipment
Additive Manufacturing
Fused Deposition Modeling (FDM)
Additive Manufacturing
Material Deposition Layer by Layer Courtesy: http://www.growit3d.com/wp-content/uploads/2012/09/FDM-Nozzle-GROWit-Good-Enough-for-NASA.jpg
Jalebi Making
Additive Manufacturing
Additive Manufacturing
Additive Manufacturing
Additive Manufacturing
Fused Deposition Modeling (FDM)
Additive Manufacturing
Selective Laser Sintering (SLS)
Additive Manufacturing
Powder Jetting
Additive Manufacturing
Stereolithography (SLA)
Additive Manufacturing
Additive Manufacturing does not require any mold as a precursor to manufacture
Additive Manufacturing
Multiple parts can be produced in one go
Additive Manufacturing
Geometric complexity is not a limitation in Additive Manufacturing
Tooling by Additive Manufacturing
Patterns for Casting
Tooling by Additive Manufacturing
Molds for Casting
Tooling by Additive Manufacturing
Patterns for Casting
Tooling by Additive Manufacturing
Direct Tooling Courtesy: 3rtpd.co.uk
Recent Metal Applications
Jet Engine (GE) Courtesy: SME
Bio-applications of Additive Manufacturing
Courtesy: Espalin et al. (Emerald),
Bio-applications of Additive Manufacturing
Biocompatible scaffold structures Courtesy: phoenixproto.com
Materials Options for Additive Manufacturing Metallic materials – Plain Carbon Steel, Tool Steel, Stainless steel, Aluminium, Copper, Titanium, Bronze, Nickel Alumides Polymers and Polymeric Composites - ABS, Nylon (Polyamide), Polycarbonate, PP, Epoxies, Glass filled polyamide, Windform, Polystyrene, Polyester, Polyphenylesulfone Others - Sand, Ceramics, Elastomers, Tungsten, Wax, Starch, Plaster
Bio Compatible Materials - Polycaprolactone (PCL), polypropylenetricalcium phosphate, (PP-TCP), PCL-hydroxyapatite (HA), polyetheretherketone-hydroxyapatite, (PEEK-HA), tetracalcium phosphate (TTCP), beta – tricalcium phosphate (TCP), Polymethyl methacrylate (PMMA)
Applications of Additive Micromanufacturing
Micro Air Vehicle
Applications of Additive Micromanufacturing
Micro Part
Applications of Additive Micromanufacturing
Dental Part
Tactile Diagrams
Thermoforming
Tactile Diagrams
Tactile Diagrams
Thermoforming with 3D printed Molds
Refreshable Braille Device
Refreshable Braille Displays
Refreshable Braille Display
Challenges in Additive Micromanufacturing Layer thickness Common layer thicknesses range in 0.050 to 0.150 mm A few processes/machines have option of layer thickness 0.010 to 0.050 mm Best available option is 0.001 mm
Feature Size
Applications of Additive Micromanufacturing
Scaffold Porosity Structure
Challenges in Additive Micromanufacturing Layer thickness
Feature Size Control Orientation Control Porosity Control Raw Material Size Control Heat Affected Zone Micro and Nano Additives Manufacturing Assemblies
AM Processes
AM Processes Courtesy: http://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing/
Additive Manufacturing
Fused Deposition Modeling (FDM)
Additive Manufacturing
Selective Laser Sintering (SLS)
Additive Manufacturing
Powder Jetting
Additive Manufacturing
Stereolithography (SLA)
Challenges in Additive Micromanufacturing
Design for Layered
Equipment Design
Micromanufacturing
Considerations
Raw material
Process Planning
Considerations
Considerations
Additive Micromanufacturing
MICA Freeform
Thanks. Questions?
