1.2-Types of AM 

There are 7 different types of additive manufacturing (AM)

1. Vat Photopolymerization:  A liquid photopolymer that is solidified using a UV light/laser to create a part, layer by layer.  

2. Powder Bed Fusion (PBF): A laser to sinter a powdered material, typically a thermoplastic or metal, layer by layer to create a part. 

3. Binder Jetting: A liquid binder that is selectively deposited onto a dry powder bed to bond particles of powder together, layer by layer.  

4. Material Jetting:  Jetting droplets of photopolymer materials onto a build platform. The material is then cured with UV light to solidify each layer. 

5. Sheet Lamination:  Stacking and bonding layers of material together to create a part. 

6. Material Extrusion: A thermoplastic filament, which is melted and deposited layer by layer to create a part. 

7. Directed Energy Deposition (DED):  Typically a laser or an electron beam, to melt and deposit material layer by layer to create a part.

1.2 Checkpoint

1.3 AM Applications 

Some tasks that AM is good at are

1. Complexity:  Good tasks for AM are those that are too complex or too difficult to produce using traditional manufacturing methods.  

2. Customization: AM is particularly well-suited for creating customized products. Good tasks for AM involve creating products that are tailored to individual customers' needs or preferences. 

3. Low-Volume Production: AM is a cost-effective way to produce low volumes of products. Good tasks for AM involve producing small quantities of parts or products. 

4. Material Properties: AM can produce parts with unique material properties that are difficult to achieve using traditional manufacturing methods. Good tasks for AM involve creating parts that require specific material properties. 

But, there are also tasks that AM isn't good at, and those are

1.  Simple Geometries: AM is not always the most efficient method for producing simple geometric shapes. These can often be produced more quickly and cost-effectively using traditional manufacturing methods such as injection molding or casting. 

2. High-Volume Production: AM can be time-consuming and expensive for high-volume production runs. For example, producing thousands of identical parts may be better suited to traditional manufacturing methods. 

3. Large, Heavy, or Bulky Parts: AM is typically limited in terms of the size and weight of the parts it can produce. Producing large, heavy, or bulky parts may require specialized equipment or multiple print jobs. 

4. Parts with Strict Tolerances: AM can produce parts with high accuracy and precision, but there are limits to the tolerances that can be achieved. 

Industrial Application for AM

Aerospace: Manufacturing lightweight and complex components for aircraft and spacecraft, reducing weight and improving fuel efficiency. It also enables the rapid production of prototypes and replacement parts.  

Automotive: Production of lightweight and complex parts to improve fuel efficiency and performance. It also allows for the creation of customized components and rapid prototyping for design evaluation.  

Construction: The use of AM in the construction industry has the potential to revolutionize the way buildings are designed and constructed.

Dental: Manufacturing of dental crowns, bridges, and implants with high precision and customization. It reduces production time and cost compared to traditional methods. 

Conventional Manufacturing Processes: Creation of molds, fixtures, and tooling for use in traditional manufacturing processes. AM can reduce lead times and costs associated with creating these tools.  

Medical: Production of customized implants, prosthetics, and surgical tools tailored to individual patients. 

Electronics: Production of customized electronic components, such as circuit boards, sensors, and antennas. 

Energy: Manufacturing of complex and efficient components for the renewable energy sector, such as wind turbine blades, fuel cells, and solar panel components. 

Robotics: Manufacturing of lightweight, customized, and complex robotic components that can enhance the performance and capabilities of robots. 

Bio Manufacturing: Creation of tissue structures and organs for research, drug testing, and eventually transplantation. AM allows precise control over the placement of cells and biomaterials, enabling the construction of complex biological structures. 

Non-Industrial Applications for AM

Architecture: Production of scale models and prototypes for design evaluation and communication. It allows architects to visualize and test their designs more effectively, as well as clearly chow their clients the end result before building. 

Art: Artists use AM to create intricate and unique sculptures, jewelry, and other works of art. It enables new forms of expression by allowing the production of complex shapes not possible with traditional methods. 

Assistive Devices: Production of customized and adaptive devices for individuals with disabilities, such as wheelchair components, hearing aids, and orthotics. 

Entertainment: Creation of props, set pieces, and costumes for film, theater, and television. 

Consumer Products: Creation of customized and personalized products, such as phone cases, toys, and home decor items. AM enables small-scale, on-demand production.  

Education: 3D printing is used in schools and universities to teach design, engineering, and manufacturing concepts. It fosters creativity and innovation by allowing students to prototype their ideas quickly.  

Food: 3D printing of edible materials to create intricate designs, textures, and structures. It offers new possibilities for presentation, personalization, and nutritional optimization in the culinary industry. 

Fashion/Clothing: Production of customized and intricate clothing, footwear, and accessories using a variety of materials, including polymers, textiles, and metals. It enables designers to create unique and innovative fashion items.  

Restoration and Archaeology: Recreation of historical artifacts and architectural elements for restoration and preservation purposes. AM can help maintain cultural heritage by enabling accurate reproductions of original items. 

DIY and Maker Movement: AM empowers individuals to design, create, and customize their own products at home or in makerspaces. This fosters creativity, innovation, and entrepreneurship. 

1.3 Checkpoint

Questions:

1. What industries or fields (other than the ones discussed here) do you think are particularly well-suited for the use of AM, and why? 

2. What skills or knowledge do you think will be important for future engineers and designers who will work on developing and deploying AM parts, processes, & applications?

3. Research or think of an example of AM that has radically transformed human jobs/industry/other - what overall affects did the transformation have, from a perspective of 3-Pillar Sustainability (People, Planet, & Profit)?

4. Think of a potential application for AM that is related to either your past or current work/life experiences  - what would it look like, and how would that affect your work/life?

Answers

1. Military: For prototyping of tactical equipment, that would be lightweight but durable. 

2. They should know that 3d printing takes time to get right and they will have to try over and over again to deploy AM processes

3. Small businesses like the ones on Etsy are selling 3D printed things and it has made it a lot easier to mass make little trinkets to sell. 

4. Working at Skills Inc I think that a potential application is to mix 3d metal printing and manufacturing, like metal 3d print a rough outline of parts we need to make and then machine to make the part. The 3D metal printing would harden the metal making the final part more durable.