Table of Contents
Preface v
Acknowledgements vii
About the Authors ix
1 Basics of 3D Printing Technology 1
1.1 Basic Terms and Definitions 2
1.1.1 Additive Manufacturing 2
1.1.2 The Principle of Layer-Based Processes 3
1.2 Application Levels 6
1.2.1 Direct Processes 7
1.2.1.1 Rapid Prototyping 7
1.2.1.2 Rapid Manufacturing 11
1.2.1.3 Rapid Tooling 14
1.2.2 Indirect Processes 18
1.2.2.1 Indirect Prototyping 19
1.2.2.2 Indirect Tooling 22
1.2.2.3 Indirect Manufacturing 24
1.3 Classification of Machines for Additive Manufacturing 27
1.3.1 Generic Terms for AM Machines 27
1.3.2 Classification of Machines and Properties of Parts 29
1.4 Conclusions 30
1.5 Questions 30
2 Additive Manufacturing Processes/3D Printing 33
2.1 Direct Additive Processes 33
2.1.1 Polymerization 36
2.1.1.1 Laser-Stereolithography (LS) 37
2.1.1.2 Polymer Printing and Polymer letting 39
2.1.1.3 Digital Light Processing 41
2.1.1.4 Micro Stereolithography 42
2.1.2 Sintering and Melting 43
2.1.2.1 Laser Sintering/Selective Laser Sintering (LS/SLS) 43
2.1.2.2 Powderbed Fusion (PEF), Selective Laser Melting (SLM) 47
2.1.2.3 Electron Beam Melting 48
2.1.3 Extrusion/Fused Layer Modeling 49
2.1.4 Powder-Binder Process 53
2.1.4.1 3D Printer - 3D Systems/Z Corporation 53
2.1.4.2 Metal and Sand Printer - ExOne 55
2.1.4.3 3D Printing System - Voxeljet 57
2.1.5 Layer Laminate Manufacturing (LLM) 58
2.1.5.1 Laminated Object Manufacturing (LOM) 58
2.1.5.2 Selective Deposition Lamination (SDL) 60
2.1.5.3 LLM Machines for Metal Parts 61
2.1.6 Hybrid Processes 61
2.1.6.1 Controlled Metal Buildup (CMB) 62
2.1.6.2 Direct Metal Deposition (DMD) 62
2.1.6.3 Extruding and Milling - Big Area Additive Manufacturing (BAAM) 63
2.1.7 Further Processes 65
2.1.7.1 Aerosol Printing 65
2.1.7.2 Bioplotter 66
2.2 Indirect Processes/Follow-Up Processes 66
2.3 Conclusions 68
2.4 Questions 68
3 The Additive Manufacturing Process Chain and Machines for Additive Manufacturing 71
3.1 Data Processing and Process Chains 71
3.1.1 AM Process Chain 71
3.1.1.1 Process Chain: Rapid Prototyping 73
3.1.1.2 Process Chain: Rapid Manufacturing 75
3.1.2 Data Structure, Errors, and Repair 76
3.2 Machines for Additive Manufacturing 80
3.2.1 Personal Printers 81
3.2.1.1 Fabber and Do-h-Yourself Printers (DIY) 81
3.2.1.2 Desktop Printers 84
3.2.2 Professional Printers 87
3.2.3 Production Printers 88
3.2.4 Industrial Printers 91
3.3 Conclusions and Outlook 97
3.4 Questions 97
4 Applications of Additive Manufacturing 101
4.1 Automotive Industry and Sub-Suppliers 102
4.1.1 Automobile - Interior Components 102
4.1.2 Automobile - Exterior Components 105
4.2 Aerospace Industry 107
4.3 Consumer Goods 109
4.4 Toy Industry 114
4.5 Art and History of Art 116
4.6 Mold and Die Making (Rapid Tooling) 119
4.7 Medical Engineering 121
4.8 Architecture and Landscaping 126
4.9 Miscellaneous Applications 131
4.9.1 Mathematical Functions 131
4.9.2 3D Decoration Objects and Ornaments 131
4.9.3 Aerodynamic and Freeform Objects 132
4.10 Conclusions 133
4.11 Questions 134
5 Perspectives and Strategies of Additive Manufacturing 137
5.1 Potential of Additive Manufacturing 137
5.1.1 Complex Geometries 139
5.1.2 Integrated Geometry 141
5.1.3 Integrated Functions 143
5.1.4 Multi-Material Parts and Graded Materials 149
5.2 Strategies of Additive Manufacturing Processes 152
5.2.1 Customized Mass Production 153
5.2.1.1 One-of-a-Kind and Small Batch Production 153
5.2.1.2 Individualization 154
5.2.1.3 Personalization 157
5.2.2 Personal Production 160
5.2.3 Distributed Individualized Production 162
5.3 Conclusions 163
5.4 Questions 164
6 Materials and Design 167
6.1 Materials 167
6.1.1 Anisotropic Properties 169
6.1.2 Isotropic Basic Materials 171
6.1.2.1 Plastics 173
6.1.2.2 Metals 176
6.1.2.3 Ceramic Materials 178
6.1.2.4 Composite Materials 179
6.1.2.5 Further Materials 180
6.1.3 Graded Materials and Composite Materials 181
6.2 Construction - Engineering Design 182
6.2.1 Tolerances - From the Digital Design to the Part 183
6.2.2 Design Freedom 183
6.2.3 Relative Fit 184
6.2.4 Flexures, Hinges, and Snap-Fits 184
6.2.5 Orientation and Positioning of Parts in the Build Space 185
6.2.6 Bores (Holes), Gaps, Pins, and Walls 186
6.3 Selection Criteria and Process Organization 189
6.4 Conclusions and Outlook 190
6.5 Questions 191
7 Glossary 195
Index 203
