The additive manufacturing process uses multiple processes to produce an item. Some of these processes include Laser-based additive manufacturing, Direct metal laser sintering, and Electron Beam DED. Binder jetting is another additive manufacturing technique that uses a liquid binder that binds the powder material to a print head. Once the binder binds the powder, the printer moves over it to spread the layer of powder. This process continues until the final item is solidly embedded in the unused powder.
Material extrusion
Material extrusion in additive manufacturing processes is an emerging technology. This type of manufacturing process has a wide range of applications. For example, material extrusion can be used to make 3D printer parts with materials such as carbon fiber or Kevlar. The process also allows users to embed metallic particles or carbon fiber into filament.
The material extrusion process is a promising approach to manufacturing with polymers. It allows the user to select the right amount of thermoplastic material for the job and then extrude it one layer at a time. It is particularly useful in the production of polypropylene components.
Laser-based additive manufacturing
Laser-based additive manufacturing processes have the potential to improve the performance and efficiency of a product, while reducing manufacturing costs. This paper presents a comprehensive review of these technologies for manufacturing metal parts, covering their underlying principles, mechanical properties, thermal behavior, and process parameters. It also discusses uncertainties associated with laser-based additive manufacturing processes.
In the process, a laser beam is guided through a nozzle, generating a melt pool on a base material. The molten powder then solidifies into a single weld bead.
Electron Beam DED
DED is an additive manufacturing process that uses four different types of heat sources to build objects. Each source is directed towards a particular feedstock, which can be either wire or powder. The feedstock is then melted using an energy source, usually an electron beam. This produces a large pool of melt that is directed around the toolpath. The melt pool then freezes to form a solid metal bead.
To operate the electron beam, a vacuum must be present, which prevents the powder from oxidizing when heated. Once the part is formed, the material can be reused. This process is commonly used in the aerospace industry, where it is often used in parts of the rocket engine.
Material jetting
Material jetting is an additive manufacturing process that can create 3D objects in a variety of materials. It’s ideal for creating visual and haptic prototypes as well as tooling and casting. However, it’s not usually recommended for functional components. Depending on the material and the desired finish, there are many different methods to use this process.
Material jetting is a type of 3-D printing process that produces full-colour, multi- material objects. It uses a printhead with multiple nozzles that deposit different materials in varying colors. The resulting objects have a wide range of material properties and are usually quite complex. Unlike other 3D printing technologies, material jetting can produce parts with a smooth surface finish and tiny features.
Powder bed fusion
Powder bed fusion (PBF) is an additive manufacturing process which uses powder as a build medium. Unlike traditional machining processes, this method does not use support structures for parts. Instead, parts are built directly on the build plate.
Powder build chambers can be separate replaceable cartridges or built-in hoppers. The cost of these chambers has declined significantly over the past few years.
Powder bed fusion has the potential to be a cost-effective method for producing plastic parts in mass quantities. This technology is suitable for both prototypes and initial runs of plastic parts intended for injection molding. It can print complex parts, including movable joints and digital foam, with minimal postprocessing.
