Getting Started with Additive Manufacturing

In this chapter, we will discover a new production technique, 3D printing, also known by its more technical name, additive manufacturing.

In contrast to every other manufacturing technology that produces objects by removing material, this manufacturing method creates a component by adding material – hence the name additive manufacturing.

This relatively new set of technologies has got cheaper and cheaper in recent years; as a result, 3D printing is now starting to overlap with traditional technologies for an increasingly wider range of production needs.

To become a better designer, it is important to be aware of alternatives to traditional legacy techniques. The goal of this chapter is to introduce you to the main printing technologies and their differences to help you understand which one may fit your needs best.

In this chapter, we will cover the following topics:

• Introducing additive manufacturing
• Exploring...

Technical requirements

This chapter is a fresh restart on a new manufacturing technique; therefore, there aren’t special requirements. However, having read Chapter 1 and Chapter 6 will enhance your understanding of additive manufacturing’s potential.

Introducing additive manufacturing

Additive manufacturing is a relatively recent manufacturing technology, dating back to the 1980s. As always, it is a bit difficult to give strict definitions, but let’s just say that most traditional production processes rely on removing unwanted material from a solid block of raw material (as a sculptor would do with a block of marble to create a statue).

Additive manufacturing is completely different; instead of removing material from a block, it focuses on creating the needed part by stacking very thin layers, one on top of the other.

Figure 14.1: An example of 3D printing

Since a 3D-printed object is created layer by layer, it is possible to create complex shapes not only on the outside of the part but also on the inside. Looking at the preceding figure, we can see an inner honeycomb pattern that reduces the overall weight of the part without compromising too much of its stiffness; such reinforcement can...

Exploring the pros and cons of 3D printing over conventional manufacturing processes

In this section, we will discuss most of the key features of 3D printing along with its advantages and drawbacks.

The pros of 3D printing

Additive manufacturing is not just a new manufacturing process that allows us to create parts in different ways. Additive manufacturing established a brand-new approach to part design that keeps opening new perspectives; it is a really complex field, rich with different technologies and applications under continuous development.

Complex shapes

One of the strongest arguments in favor of additive manufacturing is its flexibility to create very complex shapes, its potential extending way beyond the capabilities of any other technology. The wide range of feasible shapes achieved is so incredible that it has opened the doors to a brand-new design approach that is often paired with 3D printing.

Let me introduce you to generative design.

Giving a precise...

Comparing different 3D-printing technologies

Choosing the proper additive technology for our project is essential if we want it to seriously compete with other production techniques. That’s why we are about to discuss all of them in detail now.

Fused deposition modeling

Fused Deposition Modeling (FDM) is the cheapest additive manufacturing process and, therefore, is the most common technology used by small companies and hobbyists.

In the following diagram, we can find a basic simplification of the process:

Figure 14.7: The FDM process

First, the printing material is supplied via a large spool of plastic filament (1). This filament is then forced into a hot end extruder (2) that melts the plastic and deposits a thin layer of material on the build plate (3).

Note that the interior of the part (4) is not solid, so by using this technology, it is possible to create a honeycomb infill. This type of infill pattern reduces the overall weight...

Summary

This concludes the chapter – I hope that your journey with additive manufacturing will be a source of new ideas and a starting point to discover different approaches to part design.

Let’s recap together what we discovered during this chapter. At first, we discussed what additive manufacturing is and how it is different from other legacy production processes. After this, we explained in which scenarios additive manufacturing should be considered a possible alternative to other technologies. Most notably, we found out why 3D printers are a valuable solution for prototypes and the advantage of additive flexibility in just-in-time supply chains.

In the final section, we analyzed one by one the most common printing technologies (FDM, SLS, and SLA), comparing their features and drawbacks. Understanding all these points is very important; sometimes, a designer is bound to old ideas or old shapes driven by legacy manufacturing techniques. Grasping the innovation...