Additive Manufacturing Technology

Additive Manufacturing (AM) is a term used to describe the full process chain involved in selectively adding material and generating geometries in 3 dimensions. AM is often referred to as 3D printing for this reason.

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Additive Manufacturing Technology
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Introduction to Additive Manufacturing (AM)

Within additive manufacturing (AM), there are seven main varieties of manufacturing styles. We will cover them individually later.

AM had been thought of as a concept since the mid-20th century, specifically from sci-fi writer Murray Leinster in 1945. After this, it wasn’t until 1971 when Johannes F. Gottwald filed a patent for a “Liquid metal recorder” that AM was nothing more than a pipe dream. This “liquid metal recorder” used liquid inks that had been electrically charged to be forced through a nozzle using magnetic forces. Unfortunately, the patent ended without any valuable results. The next implementation came about in 1981 with Japanese inventor Hideo Kodama, which was the foundations for current stereolithography (SL/SLA) style printing. This involved a vat of photosensitive liquid polymer which is solidified by ultraviolet rays. Interestingly, the description of the product was a “rapid prototyping device” which to many of us is a good description for the AM industry. The patent for this didn’t go through due to financial reasons.

The next breakthrough was from three French inventors in 1984 with a similar method to Hideo. Unfortunately, due to some technical issues with the patenting office, the patent was delayed from being pushed through, so Alain Le Méhauté, Olivier de Witte and Jean Claude André all missed out on the ownership of the title the fathers of 3D printing which is credited to Chuck Hull. Chuck patented the SLA technology process three weeks after the three forementioned scientists but got it approved sooner due to the three French inventors parent company, Alcatel, dismissing the patent before it went through processing due to a “lack of business perspective”.

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AM Timeline

Drag to view key milestones in AM

START

1945

AM as a concept, Murray Leinster
“Things Pass By”

1971

Johannes F. Gottwald patent
“Liquid metal recorder”

1981

Hideo Kodama patent
“Rapid prototyping”

1984

Alain Le Mahaute, Olivier de Witte and Jean Claude Andre patent

1986

Chuck Hull patent “Apparatus for production of three-demensional objects by stereolithography”

1988

S. Scott Crump founds Stratasys and the FDM process

1995

Fraunhofer Society develops the SLM process

2009

FDM printing process patent expires

2017

AMS founded by Robert Higham

2023

AMS creates the Additive Manufacturing AcademyTM (AMA)

2024

AMS expands into new purpose built North West AM Hub

Glossary

This glossary offers clear and concise definitions that will help you navigate the intricacies of this innovative technology. Whether you’re new to the field or looking to refresh your knowledge, the glossary serves as a valuable resource to enhance your comprehension and engagement with the material. Don’t miss out on this opportunity to expand your expertise!

Additive Manufacturing

The process of joining materials to make parts from 3D model data.

Computer Aided Design

The use of computer-base software to aid in design process

Design for Additive Manufacturing

The methodology of creating, optimising, or adapting the form and function of a part, assembly, or product to take full advantage of the benefits of additive manufacturing processes.

Finite Element Analysis

A computational method for predicting how a product reacts to forces, vibrations, heat, fluid flow and other physical effects.

Generative Design

A design method that uses algorithms and sometimes artificial intelligence to generate multiple design solutions based on specific design criteria and constraints.

Topological Optimisation

A mathematical method which spatially optimises the distribution of material within a defined domain, by fulfilling given constraints previously established and minimising a predefined cost function.

Abbreviations

  • ABS Acrylonitrile Butadiene
  • PBT Polybutylene Terephthalate
  • AM Additive Manufacturing
  • PC Polycarbonate
  • CAD Computer Aided Design
  • PEEK Polyether Ether Ketone
  • CT Computed Tomography
  • PLA Polylactic Acid
  • DED Directed Energy Deposition
  • PPS Polyphenylene Sulfide
  • DfAM Design for Additive Manufacturing
  • PSD Particle Size Distribution
  • EBM Electron Beam Melting
  • QC Quality control
  • FDM Fused Deposition Modelling.
  • SLM Selective Laser Melting
  • FEA Finite Element Analysis
  • SLS Selective Laser Sintering
  • HIP Hot Isostatic Pressing
  • STEP/STP Standard for the Exchange of Product Data
  • ISO International Organisation for Standardisation
  • STL Standard Tessellation Language

The American Society for Testing of Materials (ASTM) created the current categorisation of the different types of AM technology.

Below we have a list, graphic and some details of the 7 main techniques for AM.

Download AM technology overview
different types of AM technology

AM Technology

AMS Readiness Level

We have also allocated an AMS AM readiness level which is our opinion on where we feel the technique is currently at with respect to:

  1. Material availability
  2. Scalability
  3. Complexity
  4. Material readiness level
  5. Productivity
  6. Capability to be a step change in manufacturing

AMS’ AM readiness level is set to the following: 1= R&D, 5=full industrial and production readiness.

Binder Jetting

Binder Jetting

A process in which a liquid bonding agent is selectively deposited to join powder materials.

AKA

Solid freeform fabrication (SFF)

Materials

Metals, ceramics and polymers

Applications

Prototyping, tooling, sand casting, art and functional parts

AM readiness level:
0       5
Directed Energy Deposition@2x

Direct Energy Disposition (Type 1)

A process in which focused thermal energy is used to fuse materials by melting as they are being deposited.

AKA

DED, laser cladding, laser additive manufacturing (LAM), Wire arc additive manufacturing (WAAM), Laser metal deposition (LMD)

Materials

Metal and polymers

Applications

Repairing, prototyping, tooling, functional parts

AM readiness level:
0       5
Directed Energy Deposition@2x

Direct Energy Disposition (Type 2)

A process in which kinetic energy is used to fuse materials as they are being deposited.

AKA

DED, Blown powder, Friction stir welding (FSW)

Materials

Metals and polymers

Applications

Repairing, prototyping, tooling, functional
parts

AM readiness level:
0       5
Material Extrusion@2x

Material Extrusion

A process in which a liquid bonding agent is selectively deposited to join powder materials.

AKA

Fused deposition modelling (FDM), fused filament fabrication (FFF)

Materials

Bound metals, bound ceramics and polymers

Applications

Prototyping, tooling, art, functional parts

AM readiness level:
0       5
Material Jetting@2x

Material Jetting

A process in which droplets of build material are selectively deposited.

AKA

Multi-jet modelling (MJM), polyjet printing.

Materials

Polymers

Applications

Prototyping, art, tooling and functional parts

AM readiness level:
0       5
Powder Bed Fusion@2x

Powder Bed Jetting

A process in which thermal energy selectively fuses regions of a powder bed.

AKA

Selective laser sintering, selective laser melting (SLM), direct metal laser sintering (DMLS), electron beam melting (EBM)

Materials

Metals

Applications

Prototyping, tooling, art and functional parts

AM readiness level:
0       5
Sheet Lamination@2x

Sheet Lamination

A process in which sheets of material are bonded to form an object.

AKA

Sheet metal additive manufacturing (SMM), laminated object manufacturing (LOM)

Materials

Metals, polymers and papers

Applications

Prototyping, art and functional parts

AM readiness level:
0       5
Vat Photopolymerisation@2x

Vat Photo Polymerisation

An additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerisation.

AKA

Stereolithography (SLA), digital light processing (DLP), continuous liquid interface production (CLIP)

Materials

Polymers, resins

Applications

Prototyping, tooling, art, functional parts

AM readiness level:
0       5
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