Additive Manufacturing in Industry 4.0

Overview

• Additive Manufacturing is a major advancement of Industry 4.0.
• Comprises different processes using various materials for innovative production possibilities.
• Three primary steps: Design, Slice, and Print.

Design Phase

• Creation Methods:
  • Original concept using Computer-Aided Design (CAD) software.
  • Selecting from existing designs in libraries.
  • 3D scanning of existing parts.
• Output: Each method produces a 3D model saved as an STL file.

Slicing Phase

• Slicing Software prepares the model for printing.
• Model is sliced into layers.
• A path is generated for the printer to follow.
• Various parameters can be adjusted during this stage.

Printing Phase

• Additive Manufacturing adds materials layer by layer, using only necessary materials (unlike traditional methods that remove and scrap materials).
• Materials used vary widely: metals, sand, concrete, human tissue, etc.

Processes in Additive Manufacturing

1. Binder Jetting:

   • Applies a liquid bonding agent to powdered material (plastic, metal, glass, sand, ceramic).
   • Thin layers of powder are rolled out, and the binder is applied.
   • The process is repeated layer by layer.
   • Loose powder is removed post-printing.

2. Directed Energy Deposition (DED):

   • A buildup welding process using powder or wire.
   • Material is melted by an energy source (laser, electron beam, etc.) and deposited layer by layer.
   • Can create new parts, add features, or repair existing parts.

3. Material Extrusion:

   • Functions like a hot glue gun; material is heated and extruded through a nozzle.
   • Layered deposition onto a build platform.
   • Can include multiple materials within a single build (support structures).

4. Material Jetting:

   • Similar to inkjet printing; selectively deposits material droplets.
   • Cured by an energy source (UV light).
   • Excels in producing parts with excellent detail and surface finish.
   • Capable of full-color parts with multiple materials.

5. Powder Bed Fusion:

   • Powder material spread and selectively fused with thermal energy (laser/electron beam).
   • Enables production of complex shapes supported by surrounding powder.

6. Sheet Lamination:

   • Sheets of material are stacked, cut, and bonded to form an object.
   • Utilizes various materials (paper, polymers, metals) and bonding methods (adhesives, heat, welding).

7. Photopolymerization:

   • Involves large vats of liquid photopolymer resin solidified by light exposure.
   • Produces extremely fine details and high-resolution parts.

Applications of Additive Manufacturing

• Prototyping and models.
• Tooling for repairs.
• Creation of end-use parts.

Future of Additive Manufacturing

• Still in early stages within Industry 4.0.
• Constantly evolving with limitless possibilities.
• Encouragement to explore projects at America Makes for innovation.

Conclusion

• Additive manufacturing recalibrates possibilities in the industry.
• Potential for future advancements is vast and encourages exploration.