Additive Manufacturing: Definition, Process, Advantages, and Applications
By Prodways Group
Published on 06/06/2024
10 min
History
What is additive manufacturing?
Additive manufacturing, or 3D printing, has quickly become a technological revolution in the field of industrial production. This technology involves layering successive materials to create three-dimensional (3D) objects from digital data. Additive manufacturing offers enhanced design and customization possibilities, providing greater freedom in creation.
The Evolution of Additive Manufacturing
Although recent in its industrial application, additive manufacturing finds its origins in the 1980s in Japan with the experiments of Dr. Hideo Kodama, which paved the way for stereolithography. Over the decades, additive manufacturing has significantly progressed, evolving from a mere technological curiosity to a full-fledged production method.
How additive manufacturing works ?
To understand how additive manufacturing works, it is essential to recognize that the manufacturing process revolves around several key stages, from design to post-production, each with its own specificities and requirements.
The Additive Manufacturing Process
Additive manufacturing takes place in five distinct phases following a methodical process:
The creation of a 3D model in computer-aided design (CAD) software. The design phase is crucial, requiring specific consideration of the capabilities and limitations of 3D printing. Designers must think not only about the object’s aesthetics but also about its functionality, strength, and structural integrity.
The 3D model is then digitally sliced into multiple horizontal layers, a process known as “slicing,” which generates a file containing precise instructions for the 3D printer. The model is usually converted into an STL file.
The process continues with the transfer of these digital data to the 3D printer. Parameters such as temperature, printing speed, and axis movement are adjusted to match the specifications of the configuration file.
Once the machine is ready, the production phase begins. In a precise mechanical ballet, the machine deposits or solidifies the material layer by layer, following the paths defined by the STL file. With each layer, the material is added or hardened with extreme precision to exactly match the digital model. It is through this meticulous accumulation that the object gradually takes shape and structure.
When the printing is complete, post-processing follows according to safety standards. Once the object has cooled and reached a stable state, it can be carefully extracted from the machine. This operation often requires specific tools and technical expertise, especially for complex parts or those made with delicate materials. At this stage, the object may still require post-printing treatments, such as polishing, painting, or assembly with other components, to achieve its final form and function.
The Different 3D Printing Processes
Today, there are multiple additive manufacturing technologies available. The diversity of 3D printing processes opens up a wide range of possibilities regarding usable materials and potential applications. Each technique has its strengths and constraints, which influence the choice of the process depending on the project.
Vat Photopolymerization
Creation Date: 1984
Vat photopolymerization involves using a resin placed in a reservoir and a light source to solidify the resin. This process includes several techniques such as Stereolithography (SLA), Digital Light Processing (DLP), and MSLA.
It is the second most common process, remaining relatively affordable, and is the only one, along with extrusion, used in office settings. The use of light over the entire surface ensures an excellent level of precision, a smooth surface, and tight tolerances without requiring post-processing, in addition to reducing print time. However, the raw material is highly toxic, and the size of the produced objects is quite limited. Additionally, post-processing operations are necessary to prevent the degradation of the piece.
Stereolithography uses a UV laser to polymerize a photosensitive liquid resin layer by layer. This technique is known for its high precision and ability to produce parts with smooth and detailed surfaces. Stereolithography (SLA) has led to the development of new technologies, including DLP and MSLA, which optimize the use of light to solidify the resin.
Thus, DLP uses a light projector on the surface of the resin, modulated by a set of microscopic mirrors. This approach allows the platform to rise, solidifying the resin layer by layer.
The Masked Stereolithography Apparatus (MSLA), on the other hand, uses an LCD screen as a mask to precisely shape the light, allowing for selective and rapid photopolymerization of the desired areas. This offers greater precision and efficiency compared to the point-by-point process of SLA.
Possible applications of these technologies: Dental, Jewelry, Modeling, Healthcare, Industry, Art.
Fused Deposition Modeling (FDM)
Creation Date: 1988
The FDM process was developed by Scott Crump in the late 1980s and patented in 1989. Scott Crump subsequently founded the company Stratasys to commercialize this technology.
Fused Deposition Modeling(FDM), also known as Fused Filament Fabrication (FFF), is an accessible and cost-effective additive manufacturing technique. It works by heating a thermoplastic filament until it melts. The printer’s extruder, a heating element, pushes this melted plastic through a nozzle and carefully deposits it onto the print bed, layer by layer. As the plastic cools, it solidifies quickly, allowing the object to be gradually built up. This method is widely used in both domestic and professional applications due to its simplicity and relatively low cost.
Possible applications of this technology: Rapid Prototyping, Industry, Architecture and Design, Hobbies, Aerospace, Automotive, Electronics, and Healthcare.
Powder Bed Sintering and Fusion
The first developments in the field of Selective Laser Sintering (SLS) for polymers began in the 1980s. The technology was patented in 1989 by Dr. Carl Deckard and Dr. Joe Beaman from the University of Texas at Austin.
Additive manufacturing technologies known as powder bed fusion, such as SLS, DMLS, SLM, and EBM, use lasers or electron beams to fuse powdered materials or metals layer by layer, enabling the creation of complex and durable parts.
SLS(Selective Laser Sintering) uses polyamides and other plastics. The selective fusion of powder particles by a laser traces the outline of the part, gradually lowering the build platform to add new layers of powder.
DMLS and SLM, on the other hand, focus on metals: DMLS welds metal powders without reaching the melting point for high precision, while SLM completely melts them, making it ideal for pure metals like aluminum, offering lightness and robustness to the parts.
EBM stands out by using an electron beam in a high-temperature and vacuum environment. This method minimizes residual stresses and reduces the risk of distortion. These advanced processes support the creation of durable mechanical components, from prototypes to spare parts, with a variety of materials.
The Multi Jet Fusion (MJF) technology, created by HP in 2016, uses an innovative approach where an inkjet array deposits fusing and detailing agents onto a layer of polymer powder. Once applied, these agents are heated to transform the powder into a solid layer, without the need for a laser. This process significantly improves the resolution of the manufactured parts, thanks to the application of detailing agents around the contours of the objects, making it possible to produce parts with realistic and detailed finishes.
Possible applications of these technologies: Aerospace, Medical, Automotive, Prototyping, Design, Fashion, Art, Jewelry, and Industry.
Binder Jetting 3D Printing
This technology was developed at the Massachusetts Institute of Technology (MIT) and patented in the early 1990s. It sprays a liquid binder onto a layer of powdered material, binding the particles together to create a section of the object, and then repeats the process for successive layers.
Binder Jetting 3D printing can be done with metal powder, sand, ceramic, or polymer. Although less common than other materials, polymer printing offers an alternative to techniques like FDM or SLS for certain applications. Some binder jetting systems can print in color by adding pigments to the binder. This technique is particularly useful for architectural models, figurines, and prototypes that benefit from a realistic visual representation.
Possible applications of these technologies: Architecture, Rapid Prototyping, Product Design, Mold Production, Medicine and Dentistry, Art, Jewelry, Education.
Material Jetting
This process was developed in the 1990s, with companies like Objet (now merged with Stratasys) among the first to commercialize it. It creates objects by depositing small droplets of material, which are then cured by UV light, offering remarkable capabilities. Here are the various advanced techniques:
Among these, PolyJet technology stands out for its ability to print multiple materials and colors simultaneously, allowing for the creation of complex parts with varied mechanical and aesthetic properties.
Similarly, MultiJet technology excels due to its high precision and ability to handle a variety of materials, including plastics and waxes, making it ideal for applications requiring extremely fine details.
Finally, the Drop on Demand (DOD) technique is particularly valued for its efficient material management and ability to print with less waste, which is essential for printing ceramics and metals.
These Material Jetting technologies are crucial for pushing the boundaries of innovation in product design and rapid prototyping.
Possible applications of these technologies: Packaging, Pharmaceutical Industry, Industrial, Plumbing, Rapid Prototyping, Medical, Art, Electronics.
Sheet Lamination or Laminated Object Manufacturing (LOM)
The origins of this process date back to the 1990s, with various variants having been developed since. Sheet Lamination, also known as Laminated Object Manufacturing (LOM), is an additive manufacturing technique where sheets of material are stacked and bonded layer by layer to form an object.
Sheet Lamination encompasses several innovative technologies, each suited to specific applications.
Among them, Laminated Object Manufacturing (LOM) stands out for using sheets of paper, plastic, or metal, which are cut by laser or with an automated knife to match each layer of the desired part, with an adhesive to bond the layers together. This method is ideal for quick and cost-effective prototypes.
On the other hand, Ultrasonic Additive Manufacturing (UAM) fuses metal sheets using ultrasonic vibrations that generate heat through friction, allowing the creation of metal composites without altering the thermal properties of the materials used.
Finally, Selective Deposition Lamination (SDL), similar to LOM but often used with paper, employs an adhesive to bond the layers and a laser for cutting, providing an efficient method for applications requiring fine details and low-cost production.
Possible applications of these technologies: Packaging, Pharmaceutical Industry, Industrial, Plumbing, Rapid Prototyping, Architecture, Mold and Model Making, Education, Automotive.
Directed Energy Deposition (DED)
Although similar techniques for surface coating existed since the 1970s, their application to additive manufacturing began to emerge in the 1990s.
Directed Energy Deposition (DED) is an additive manufacturing process that involves melting material in the form of powder or wire as it is deposited by a nozzle onto a surface. An energy beam, such as a laser or electron beam, is used to melt the material and build the object layer by layer.
This technique encompasses several advanced methods, each suited to specific industrial applications.
Among them, Laser Engineered Net Shaping (LENS) stands out for its ability to repair and reinforce metal parts by using a laser to melt metal powder, making it ideal for aerospace components.
Electron Beam Additive Manufacturing (EBAM), which uses an electron beam in a vacuum, is perfect for the rapid construction of large structures due to its efficiency in material deposition.
Direct Metal Deposition (DMD) offers remarkable flexibility with the ability to deposit different materials simultaneously, allowing the production of parts with graded properties.
Finally, Wire Arc Additive Manufacturing (WAAM) focuses on efficiency and cost reduction by using metal wires to fabricate large parts, often used in the maritime and construction sectors. These technologies illustrate the adaptability and efficiency of additive manufacturing to meet the demands of various industries.
Possible applications of these technologies: Large parts, Complex geometry parts, Aerospace, Automotive and Medical, Rapid prototyping.
Advantages of Additive Manufacturing
Customized 3D Printing
Customization is one of the most remarkable features of 3D printing. This technology offers unprecedented flexibility to tailor each piece to the specific needs of the end user. Through digital modeling, it is possible to design custom objects that precisely match the required dimensions and specifications. Besides customization, additive manufacturing opens the door to design complexity that pushes the boundaries of traditional engineering. With 3D printing, it is now possible to create complex geometries.
Time Savings
3D printing radically transforms the production approach, allowing companies to drastically reduce development and manufacturing lead times. This technology facilitates rapid iterations and continuous testing. The simplification of the manufacturing process speeds up the market introduction of innovations, providing companies with a significant competitive advantage. They become more agile, able to quickly respond to market needs. Additive manufacturing is, therefore, a powerful lever for increasing productivity and maintaining an edge in today’s dynamic business environment.
Additive 3D Printing: A More Sustainable Mode of Production
3D printing, also known as additive manufacturing, is a virtuous alternative manufacturing method that differs from traditional subtractive manufacturing techniques (machining, sculpting, milling, drilling, etc.). By creating physical objects through the layering of different materials, it eliminates all deemed unnecessary parts and significantly reduces the amount of wasted material.
3D Printing for Everyone
Additive manufacturing is limitless and allows for the design of parts, prototypes, and series for numerous sectors such as:
Medical: 3D printing promotes the rapid production of orthotics and prosthetics (for dental, podiatry, and hearing applications, for example), custom implants, anatomical models for surgical planning, specific instruments, and treatments and medications tailored to individual needs. Beyond these proven applications, today 3D bioprinting paves the way for the production of customized functional tissues and organs, which should reduce waiting times for transplants and offer new treatment possibilities.
Industry: 3D printing for industry facilitates the manufacturing of custom parts, reduces production costs and lead times, and optimizes design processes. Some companies use it to produce complex aerospace components and reduce engine weight to improve efficiency. This technology is expected to be increasingly integrated into production lines, as it enables more agile and customized manufacturing, as well as a reduced carbon footprint through optimized material usage.
Luxury: 3D printing has also found its place in the luxury sector, as it provides luxury brands the freedom to create increasingly aesthetic, unique, and complex pieces to meet the specific needs of their most demanding clients. Renowned jewelers, for example, are already using this method to design rings or watches with extremely fine details and precious materials. For designers, this on-demand production solution significantly reduces material waste and prevents the loss of precious materials.
Art: For artists and sculptors, it is also a preferred method as it aids in the creation of complex and unique sculptures, simplifying the prototyping process while offering more choices in materials and shapes. Some artists are already using it to create three-dimensional artworks with an unprecedented level of detail. In the future, 3D printing could further democratize creation and art by providing affordable and accessible tools to artists.
Aerospace & Naval: Additive manufacturing contributes to increased innovation and improved performance in the aerospace and naval sectors. It enables the production of lightweight complex parts, facilitates the creation of prototypes and custom components, and accelerates the design and development process. 3D printing can be used to produce on-demand spare parts, reducing storage and logistics costs.
Automotive: Ideal for the manufacturing of complex and lightweight parts, such as engine prototypes or custom components, additive manufacturing offers the potential to reduce production costs and improve vehicle performance. Some major brands are already using it to create custom parts, seat components, and more. And in the future? The automotive sector could see the emergence of entirely unique vehicles designed in 3D.
The Future of Additive Manufacturing
The financial dynamism of the sector, estimated at $15 billion in 2023 according to the SmarTech Analysis 3D Printing Market Report, is expected to experience significant growth to reach an evaluation of $35 billion by 2028. These figures confirm the sustained growth and widespread adoption of additive manufacturing. A future that is emerging through major advancements.
Does the emergence of AI have an impact on additive manufacturing?
The future trajectory of 3D printing is undeniably oriented towards increased synergy with artificial intelligence, which promises to transform this technology. By integrating AI algorithms into printing processes, additive manufacturing could see:
Enhanced optimization of printing parameters,
Automatic detection and correction of manufacturing defects,
The creation of innovative generative designs.
More advanced product customization and real-time adaptive manufacturing processes.
With rapid advancements in this field, the possibilities offered by AI in 3D printing seem promising and could pave the way for new innovations and growth in this technology.
Advancements in materials science
The materials used in additive manufacturing are at the heart of the evolution of this technology.
Research aims to develop new materials with enhanced properties: superior strength and increased flexibility, thereby contributing to the optimization of the performance of final products. These material innovations will push the boundaries of possible applications for additive manufacturing.
Current research also focuses on developing more environmentally friendly materials, such as degradable bioplastics or recycled composites, aiming to reduce waste and energy consumption associated with industrial production. Eco-design is becoming a standard, with materials designed to be reused or reintegrated into the production cycle after their useful life, thus minimizing the ecological impact throughout the value chain.
Tomorrow, advancements in the field of additive manufacturing promise a transformative revolution:
Increased printing speeds
Improved precision
Ever more advanced materials
We can expect significant advances in the production of parts of all sizes, from the smallest component to the largest structure. The increasing integration of artificial intelligence will not only optimize printing processes but also pave the way for more complex and efficient designs.
The importance of sustainability should also drive the development of environmentally friendly additive manufacturing methods. These advancements open the door to a future where additive manufacturing will become even more prevalent and efficient, while redefining production standards to explore new frontiers in design and innovation.
Ultimately, additive manufacturing is now establishing itself as a major revolution in the industrial landscape, marking a decisive turning point in how we design, create, and produce. Born from scientific curiosity in the 1980s, it has evolved into an essential production method that transcends the boundaries of aerospace, automotive, and medical fields, extending to energy, education, fashion, and even food.
This expansion is the result of its flexibility, as additive manufacturing offers innovative custom solutions that meet the specific requirements of each industry. It now positions itself as a central pillar of industrial transformation, addressing contemporary challenges and paving the way for a future rich with potential.
FAQ
1. What materials can be used in additive manufacturing?
Many materials can be used for additive manufacturing depending on the specific technology and application. These include materials such as polymers (plastics), resin, ceramic, wax, and even metal.
2. Is additive manufacturing suitable for mass production?
Yes, it allows for the production of small or large series projects in very short time frames. Although additive manufacturing is often associated with prototype production and custom manufacturing, it is increasingly being used for mass production in various industrial sectors.
3. What are the typical production timelines in additive manufacturing?
There is no typical production timeline in additive manufacturing. Production times can vary significantly depending on several factors, including the complexity of the part, its size, the type of printing technology used, the availability of machines, and the workload of the service provider. However, here are some general estimates for production times in additive manufacturing:
Simple Prototypes: For small to medium-sized parts with moderate complexity, production times can range from a few days to a week.
Custom Production Parts: For unique or small series parts requiring customization, production times can vary from a few days to a few weeks depending on the complexity and finishing requirements.
Limited Series Production Parts: For larger series, production times can range from a few weeks to a few months, depending on the production volume and machine capacity.
Large or Highly Complex Parts: Large or highly complex parts may require longer lead times due to the printing time and any necessary post-processing or finishing.
It is important to note that these timelines are general estimates and can vary based on the specific circumstances of each project. It is recommended to consult directly with Initial in additive manufacturing to obtain precise timelines based on your needs and specifications.
