Emerging Processes: 3D Printing
Resources, Processes & Materials Engineering
LECTURE 12a
Dr Tejas Bhatelia
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Lecture Outline
• Naturetoengineering?
• 3Dprinting • Why?
• Whatand • How?
• 3Dprintingandyouasengineers
• Opendiscussionandquestions
Lecture focus
Reproduced from “Materials and Man’s Needs”, National Academy of Sciences, Washington D.C., 1974.
Design manufacture assembly?
Conventional manufacturing
Advanced manufacturing (3D printing?)
Reproduced from “Materials and Man’s Needs”, National Academy of Sciences, Washington D.C., 1974.
Why should we even consider Advanced manufacturing
Improveprocessing efficiencies
Asset management Maintenance and retrofitting New plant developments
P roduction Transportation Raw material
What does improving efficiency mean?
• It must increase at least an order of magnitude performance on one or more criteria
• It should reduce the operating cost
• It should reduce the environmental footprint
• It should reduce energy or material use
• It should increase ability to perform tasks that were unable to
be done previously
• It should improve throughput
• Either of the above
• All in all it should make it better
Lets look at 3D-printed mobile cover as an example.
Every step that we transfer the form of material we need to provide energy.
The key question we should be asking is, after going through these steps have we added any value/improved efficiency?
What do you think?
Role of Advanced manufacturing
Improve Processing efficiencies is very difficult, but not impossible
It must be evaluated against the cost of energy and material
HOW? Define the problem Ideation Calculation Test Repeat Optimise
Simple fluid distributors
Principleof distribution is simple
I ndustrially distributors are designed based oneaseof manufacturing
Very difficult to manufacture
Is it always effective to use 3D printing?
Cost = energy = dollars Ifitissimpleandefficient,thenleaveit.
http://engine.scichina.com/publisher/scp/journal/SCTS/61/4/10.1007/s11431-016-9077-7?slug=fulltext
Learning Outcome Check
Describe what advanced manufacturing is, with reference to the traditional processes that convert bulk materials into end products.
List 5 criteria are used to decide between a traditional manufacturing process, and advanced manufacturing process, to make a product.
When was first 3D printing carried out?
What is 3D printing?
http://www.manufacturinglounge.com/additive-vs-subtractive-manufacturing-whats-the-difference/ 14
How does it all work?
https: / / commons.wikimedia .org / wiki/ F ile: 3d-printing -a -2014-horizonwa tching -t rend-summa r y-rep ort-9 -638.j pg
Is all 3D printing the same?
Fused deposition modelling
https://pubs.rsc.org/en/content/articlepdf/2017/cy/c7cy00615b
Laminated object manufacturing
https://link.springer.com/chapter/10.1007/978-81-322-2740-3_21
Powder bed fusion
https://pubs.rsc.org/en/content/articlepdf/2017/cy/c7cy00615b
https://pubs.rsc.org/en/content/articlepdf/2017/cy/c7cy00615b
Directed Energy Deposition
Photopolymerization
https://pubs.rsc.org/en/content/articlepdf/2017/cy/c7cy00615b
Is it always effective to use 3D printing?
Technology
Conventional manufacturing
More wastage Recycling an option
Advanced and proven Applications are wide
Plastic printing
Less wastage Non-recyclable
Low –medium
Fairly advanced Limited industrial application
Gen-1 metal printing
Very expensive Less wastage Non-recyclable to some extent
Proven process Application are limited but real
New metal printing
Cheap but hard to make at scale Less wastage Recyclable
New and limited
http://engine.scichina.com/publisher/scp/journal/SCTS/61/4/10.1007/s11431-016-9077-7?slug=fulltext
Impact of 3D printing
Impact of 3D printing
Impact of 3D printing
Impact of 3D printing and opportunities
Learning Outcome Check
Briefly describe the terms additive manufacturing and 3D printing in your own words.
List 5 types of 3D printing, indicating whether they use metals/polymers/both.
Lecture Summary
3D printing will be/is already a manufacturing tool that opens the avenues for improving process efficiencies
It is costly but with time the costs are expected to come down
Wise use of 3D printing will:
Reduce the material used in the processes
Improve energy efficiencies
Reduce capital and operating costs
Open avenues to achieve what could not be achieved previously, such as synthesis of new materials or products
It has already shown huge impact in prosthetics but in future bio printing will improve the medical science
More work needs to be done in future in terms of improving printing speeds and reducing costs.
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