Additive Manufacturing Technologies I. Gibson D. W. Rosen B. Stucker l l Additive Manufacturing Technologies Rapid Prototyping to Direct Digital Manufacturing Dr.IanGibson Dr.DavidW.Rosen DepartmentofMechanical&Production TheGeorgeW.WoodruffSchoolof Engineering MechanicalEngineering NationalUniversityofSingapore GeorgiaInstituteofTechnology 9EngineeringDrive1 813FerstDrive,N.W. Singapore117576 Atlanta,GA30332-0405 Singapore USA [email protected] [email protected] Dr.BrentStucker DepartmentofMechanical& AerospaceEngineering UtahStateUniversity 4130OldMainHall Logan,UT84322 USA [email protected] ISBN:978-1-4419-1119-3 e-ISBN:978-1-4419-1120-9 DOI10.1007/978-1-4419-1120-9 SpringerNewYorkHeidelbergDordrechtLondon LibraryofCongressControlNumber:2009934499 #SpringerScienceþBusinessMedia,LLC2010 Allrightsreserved.Thisworkmaynotbetranslatedorcopiedinwholeorinpartwithoutthewritten permissionofthepublisher(SpringerScience+BusinessMedia,LLC,233SpringStreet,NewYork,NY 10013, USA), except for brief excerpts in connection with reviews or scholarly analysis. Use in connection with any form of information storage and retrieval, electronic adaptation, computer software,orbysimilarordissimilarmethodologynowknownorhereafterdevelopedisforbidden. Theuseinthispublicationoftradenames,trademarks,servicemarks,andsimilarterms,eveniftheyare notidentifiedassuch,isnottobetakenasanexpressionofopinionastowhetherornottheyaresubject toproprietaryrights. Coverdesign: TheCoverArtworkisCourtesyofBathshebaGrossmanandBathshebaSculptureLLC Printedonacid-freepaper SpringerispartofSpringerScience+BusinessMedia(www.springer.com) Preface ThankyoufortakingthetimetoreadthisbookonAdditiveManufacturing(AM). Wehopeyoubenefitfromthetimeandeffortithastakenputtingittogetherandthat you think it was a worthwhile undertaking. It all started as a discussion at a conference in Portugal when we realized that we were putting together books with similar aims and objectives. Since we are friends as well as colleagues, it seemed sensible that we join forces rather than compete; sharing the load and playing to each others’ strengths undoubtedly means a better all-round effort and result. We wrote this book because we have all been working in the field of AM for many years. Although none of us like to be called “old,” we do seem to have decades of experience, collectively, and have each established reputations as educators and researchers in this field. We have each seen the technologies describedinthisbooktakeshapeanddevelopintoseriouscommercialtools,with tensofthousandsofusersandmanymillionsofpartsbeingmadebyAMmachines each year. AM is now being incorporated into curricula in many schools, poly- technicsanduniversitiesaroundtheworld.Moreandmorestudentsarebecoming awareofthesetechnologiesandyet,asweseeit,thereisnosingletextadequatefor suchcurricula.Wehopethatnow,withthisbook,thereis. AdditiveManufacturingisdefinedbyarangeoftechnologiesthatarecapableof translating virtual solid model data into physical models in a quick and easy process. The data is broken down into a series of 2D cross-sections of a finite thickness. These cross-sections are fed into AM machines so that they can be combined,addingthemtogetherinalayer-by-layersequencetoformthephysical part. Thegeometryofthe part istherefore clearly reproduced intheAM machine without having to adjust for manufacturing processes, like attention to tooling, undercuts,draftanglesorotherfeatures.WecansaythereforethattheAMmachine is a What You See Is What You Build (WYSIWYB) process that is particularly valuable the more complex the geometry is. This basic principle drives nearly all AM machines,withvariationsineach technologyinterms ofthetechniques used forcreatinglayersandinbondingthemtogether.Furthervariationsincludespeed, v vi Preface layer thickness, range of materials, accuracy, and of course cost. With so many variables,itiscleartoseewhythisbookmustbesolonganddetailed.Havingsaid that,westillfeelthereismuchmorewecouldhavewrittenabout. ThefirstthreechaptersofthisbookprovideabasicoverviewofAMprocesses. Withoutfullydescribingeachtechnology,weprovideanappreciationforwhyAM issoimportanttomanybranchesofindustry.Weoutlinetherapiddevelopmentof this technology from humble beginnings that showed promise but still requiring muchdevelopment,toonethatisnowmaturingandshowingrealbenefittoproduct development organizations. In reading these chapters, we hope you can learn the basicsofhowAMworks. Thenextseven chapters(Chaps.4–10) takeeach groupoftechnologiesinturn anddescribethemindetail.Thefundamentalsofeachtechnologyaredealtwithin terms of the basic process, whether it is photopolymer curing, sintering, melting, etc., so that the reader can appreciate what is needed in order to understand, develop, and optimize each technology. Most technologies discussed in this book have been commercialized by at least one company; and these machines are describedalongwithdiscussiononhowtogetthebestoutofthem. Thefinalchaptersdealwith howtoapplyAM technology indifferent settings. Firstly, we look at how the use of this technology has affected the design process considering how we might improve our designs because of the WYSIWYB ap- proach. Having said that, there are many options concerning the type of machine youshouldbuyinrelationtoyourapplication,soweprovideguidelinesonhowto select the right technology for your purpose. Since all AM machines depend on inputfrom3DCADsoftware,wegoontodiscusshowthisprocesstakesplace. These technologies have improved to the extent that many manufacturers are usingAMmachineoutputforend-productuse.CalledDirectDigitalManufacturing, thisopensthedoortomanyexcitingandnovelapplicationsconsideredimpossible, infeasibleoruneconomicinthepast.Wecannowconsiderthepossibilityofmass customization, where a product can be produced according to the tastes of an individual consumer but at a cost-effective price. This moves us on nicely to the subjectofmedicalproductsmadeusingAMwhereeachpartcanbecreatedaccord- ingtoanindividualpatient’sdata.Thenwegoontodiscusshowtofinishpartsonce theycomeofftheAMmachinesothattheycanbestsuitthefinalapplication.We complete the book with chapters on emerging areas of AM, with discussions on multiplematerialandembeddedsystems,howthesesystemsenablecreativebusi- nessesandentrepreneurstoinventnewproducts,andwhereAMwilllikelydevelop inthefuture. This book is primarily aimed at students and educators studying Additive Manufacturing, either as a self-contained course or as a module within a larger courseonmanufacturingtechnology.Thereissufficientdepthforanundergraduate orgraduate-levelcourse,withmanyreferencestopointthestudentfurtheralongthe path. Each chapter also has a number of exercise questions designed to test the reader’s knowledge and to expand their thinking. Researchers into AM may also find this text useful in helping them understand the state of the art and the opportunitiesforfurtherresearch. Preface vii Although we have worked hard to make this book as comprehensive as possible, we recognize that a book about such rapidly changing technology will not be up-to-date for very long. With this in mind, and to help educators and studentsbetterutilizethisbook,wewillupdateourcoursewebsiteathttp://www. springer.com/978-1-4419-1119-3,withadditionalhomeworkexercisesandotheraids foreducators.Ifyouhavecomments,questionsorsuggestionsforimprovement,they arewelcome.Weanticipateupdatingthisbookinthefuture,andwelookforwardto hearinghowyouhaveusedthesematerialsandhowwemightimprovethisbook. As mentioned earlier, each author is an established expert in Additive Manufacturing with many years of research experience. In addition, in many ways, this book is only possible due to the many students and colleagues with whom we have collaborated over the years. To introduce you to the authors and someoftheotherswhohavemadethisbookpossible,wewillendthisprefacewith briefauthorbiographiesandacknowledgements. Author Biographies Dr. Brent Stucker is an Associate Professor of Mechanical & Aerospace EngineeringatUtahStateUniversity.AfterreceivinghisPh.D.fromTexasA&M Universityin 1997, hejoined the Industrial &Manufacturing Engineeringfaculty of the University of Rhode Island, where he established the Rapid Manufacturing Center.In2002,hemovedtoUtahState,whereheestablishedandcontinuestolead the Additive Manufacturing Laboratory. Dr. Stucker has taught courses on AM technologies for more than 10 years, sits on the Rapid Technologies & Additive Manufacturing Steering Committee for the Society of Manufacturing Engineers, wasaSelectiveLaserSinteringUsersGroup2005“DinosaurAward”recipient,and is the current Chairman of ASTM International’s Committee F42 on Additive ManufacturingTechnologies.HisresearchfocusesonmetalAM,includingUltra- sonicConsolidation,DirectWrite,LaserEngineeredNetShaping,SelectiveLaser Sintering,andtheirapplications. Prof. David W. Rosen is a Professor in the George W. Woodruff School of MechanicalEngineeringattheGeorgiaInstituteofTechnology.Afterreceivinghis Ph.D. from the University of Massachusetts in 1992, he joined the faculty at Georgia Tech. In 1995, the Rapid Prototyping & Manufacturing Institute was started at Georgia Tech through an ARPA manufacturing education grant and Dr. Rosen was asked to become its head. Since then, he has led the additive manufacturingresearchandeducationprogramatGeorgiaTech.Heisactiveinthe SocietyofManufacturingEngineersDirectDigitalManufacturingTechGroupand the 3D Systems User Group conference. His research focuses on photopolymer processing,ink-jetprinting,anddesignforadditivemanufacturing. Dr. Ian Gibson is an Associate Professor at the National University of Singapore(NUS).OriginallyfromScotland,hemovedtoEnglandwherehegained a Ph.D. in robotics at Hull University. His teaching career started at Nottingham University, where he specialized in advanced manufacturing technology and first came to learn about the AM technology that was then called Rapid Prototyping. ix x AuthorBiographies In1994,hemovedtoHongKong,wherehehelpedestablishthetechnologyinAsia, startedtheRapidPrototypingJournalandtheGlobalAllianceofRapidPrototyping Associations. In 2005, he joined NUS, where he concentrates mostly on medical applicationsanddirectdigitalmanufacturing. Acknowledgement Dr. Brent Stucker thanks Utah State and VTT Technical Research Center of Finland,whichprovidedtimetoworkonthisbookwhileonsabbaticalinHelsinki. Additionally, much of this book would not have been possible without the many graduatestudentsandpost-doctoralresearcherswhohaveworkedwithDr.Stucker over the years. In particular, he would like to thank Dr. G.D. Janaki Ram of the Indian Institute of Technology Madras, whose co-authoring of the “Layer-Based Additive Manufacturing Technologies” chapter in the CRC Materials Processing Handbookhelpedleadtotheorganizationofthisbook.Additionally,thefollowing students’work led to one ormorethingsmentioned inthisbook:Muni Malhotra, Xiuzhi Qu, Carson Esplin, Adam Smith, Joshua George, Christopher Robinson, YanzheYang,MatthewSwankandJohnObielodan.SpecialthanksareduetoDr. Stucker’s wife Gail, and their children: Tristie, Andrew, Megan and Emma, who patiently supported many days and evenings on this book. Lastly, as the right atmosphere helps stir the creative juices, Dr. Stucker appreciates the many hours hecouldspendatCafe´ CaruselinHelsinki,Finland(whichhehighlyrecommends toanyonepassingthrough). Prof.DavidW.RosenacknowledgessupportfromGeorgiaTechandthemany graduate studentsand post-docs who contributed technicallyto the content inthis book. In particular, he thanks Drs. Fei Ding, Scott Johnston, Ameya Limaye, J. Mark Meacham, Benay Sager, L. Angela Tse, Sanjay Vohra, Hongqing Wang, ChrisWilliams,andYongYang,aswellasPatrickChang,Jane(Chen)Chu,Sarah Engelbrecht, Greg Graf, Amit Jariwala, Lauren Margolin, and Xiayun Zhao. A special thanks goes out to his wife Joan and children Erik and Krista for their patiencewhileheworkedonthisbook. Dr. Ian Gibson would like to acknowledge the support of NUS in providing sufficienttimeforhimtoworkonthisbook.L.K.Anandalsohelpedinpreparing manyofthedrawings andimagesforhischapters.Finally,hewishestothankhis lovely wife, Lina, for her patience, love and understanding during the long hours preparingthematerialandwritingthechapters.Healsodedicatesthisbooktohis father,RobertErvinGibson,andhopesheisproudofthiswonderfulachievement. xi