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Which Additive Manufacturing Process Is Right for You?

ADDITIVE-MANUFACTURING-PROCESS-MIN
Additive Manufacturing (AM) uses computer-aided design (CAD) or 3D object scanners to create accurate geometric features. In contrast to traditional manufacturing, which frequently involves milling or other processes to eliminate superfluous material, these are produced layer by layer, as with a 3D printing process.

The global additive manufacturing market is expected to grow at a 14.42 percent annual rate from USD 9.52 billion in 2020 to USD 27.91 billion in 2028, according to reports and data. Overall, the worldwide 3D printing industry is gaining traction due to various reasons, some of which are listed below.

  • Significantly, greater resolution
  • Reduced manufacturing costs as a result of recent technology breakthroughs
  • Ease of creating customised goods
  • Increasing possibilities for printing with diverse materials
  • Funding by the government for 3D printing ventures

Additive manufacturing is available or may be implemented in various procedures, which is the primary objective of this article. First, we'll look at the seven additive manufacturing processes and which one is the best to use. So let us begin.

“Don’t be afraid to go outside of your industry to learn best practices. There might be something that surprises you or inspires you to try in your line of work.”

– Emily Desimone, Director of Global Marketing at SLM Solutions

Additive Manufacturing Processes

There are numerous diverse additive manufacturing processes, each with its own set of standards. Here are the seven additive manufacturing procedures that many manufacturers consider based on their benefits from each process, or whichever approach best suits their product requirements.



Material Jetting

This additive manufacturing process is quite similar to that of conventional inkjet printers, in which material droplets are selectively placed layer by layer to build a three-dimensional object. After completing a layer, it is cured with UV radiation.


VAT Photo Polymerization

This procedure employs a technology called photo polymerization, in which radiation-curable resins or photopolymers are utilized to ultraviolet light to generate three-dimensional objects selectively. When these materials are exposed to air, they undergo a chemical reaction and solidify. Stereo lithography, Digital Light Processing, and Continuous Digital Light Processing are the three primary subcategories.


Binder Jetting

Binder jetting is a process that deposits a binding agent, typically in liquid form, selectively onto powdered material. The print head deposits alternating layers of bonding agent and construction material and a powder spreader to create a three-dimensional object.


Material Extrusion

S. Scott Crump invented and patented material extrusion in the 1980s using Fused Deposition Modeling (FDM). The continuous thermoplastic filament is fed through a heated nozzle and then deposited layer by layer onto the build platform to produce the object.


Powder Bed Fusion

Powder bed fusion procedures, particularly selective laser sintering, were the pioneers of industrial additive manufacturing. This approach melts the powdered material and fuses it using a laser or electron beam to form a tangible item. The primary kinds of powder bed fusion are direct metal laser sintering, selective laser sintering, multi-jet fusion, electron beam melting, selective laser melting, and selective heat sintering.


Sheet Lamination

Sheet lamination is a catch-all term encompassing ultrasonic additive manufacturing, selective deposition lamination, and laminated object manufacturing. All of these technologies stack and laminate sheets of material to form three-dimensional objects. After the object is constructed, the parts' undesirable areas are gradually removed layer by layer.


Directed Energy Deposition

Directed energy deposition technology employs thermal energy to melt and fuse the materials to form a three-dimensional object. These are pretty similar to welding processes, but are much more intricate.


Which Additive Manufacturing Process is best? Why?

Based on three fundamental factors, additive manufacturing techniques are categorized into seven types. First, the way material is solidified is determined first by the type of material employed, then by the deposition technique, and finally by how the material is solidified.

The end-user often chooses an additive manufacturing technique that best suits his requirements, followed by the explicit material for the process and application, out of the seven basic additive manufacturing processes.

Polymer materials are commonly used in AM techniques because they are adaptable to various procedures and can be modified to complicated geometries with high precision. Carbon-based compounds are used to strengthen polymers. Polymers, both solid and liquid, have been widely used due to the variety of shapes, formability, and end-use qualities available. Wherever the light-activated polymer contacts the liquid's surface, it instantly solidifies.

Photo polymerization, powder bed fusion, material jetting, and material extrusion are the most common additive manufacturing procedures for polymers. The materials employed in these processes can be liquid, powder, or solid (formed materials such as polymer film or filament).


How BASF is Using Additive Manufacturing


BASF is a chemical company. BASF, one of the world's major chemical companies, manufactures and provides a range of 3D printing filaments, resins, and powders within its extensive material portfolio.

The company, well-known in the 3D printing sector, has formed major material agreements with several 3D printer manufacturers, including HP, BigRep, Essentium, BCN3D, and others.

BASF went even further in 2017 by establishing BASF 3D printing Solutions GmbH (B3DPS) as a wholly-owned subsidiary to expand the company's 3D printing business. In addition, BASF stated last year that B3DPS would change its name to Forward AM.

BASF's role in the 3D printing business, however, is not limited to material development. BASF has made several investments in 3D printing companies over the years, including the acquisition of Sculpteo, one of the significant French 3D printing service bureaus, last year.

BASF sees 3D printing as having a bright future. With the growing popularity of professional 3D printers, all of these systems will eventually require robust, high-quality polymer materials to perform at their best – and BASF has been paving the way to becoming one of the leading solution providers.

Final Words


All additive manufacturing procedures are unique and helpful in their way. Still, some have additional advantages over others, such as the material used, highresolution, precision, and the ability to build complicated parts. Because of these added benefits, photopolymerization, material jetting, powder bed fusion, and material extrusion are preferred over others. Therefore, choose the AM process that is best suited to your manufacturing business and will assist you in achieving the desired final product output.


FAQs

 

What are the benefits of additive manufacturing?

AM enables manufacturers to reduce waste, prototyping costs, and customization while conserving energy and increasing production flexibility. Additionally, it benefits the supply chain and the environment, encouraging businesses to increase their manufacturing sustainability.

What is the major challenge in additive manufacturing?

Many businesses are struggling with the current difficulty of producing large and odd-sized parts using additive manufacturing. So, this can be considered a significant challenge in additive manufacturing.

What are the steps of additive manufacturing?

The additive manufacturing steps are divided into four steps as below,
  • Step1 - Design a model with CAD software
  • Step2 -Pre-processing
  • Step3 -Printing
  • Step4 - Post-processing

Spotlight

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Multek, a wholly owned subsidiary of Flex (NASDAQ: FLEX), is a leading value-add manufacturer of printed circuit board technologies offering a broad spectrum of PCB engineering and manufacturing expertise including high density interconnect, multilayer, flexible circuit and assembly solutions. Built upon a foundation of rapid response, technology leadership and high reliability solutions for PCB fabrication electronics design and manufacturing, Multek enables customers to take products to market quickly through early engineering, advanced technology new product introduction, and volume production through a full range of high-performance products, materials, and solutions.

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Toyota Supercharges North Carolina Battery Plant with New $8 Billion Investment

PR Newswire | November 01, 2023

Toyota announced a new investment of nearly $8 billion that will add approximately 3,000 jobs at Toyota Battery Manufacturing North Carolina (TBMNC). This brings total investment to approximately $13.9 billion and job creation to more than 5,000 – further supporting Toyota's multi-pathway approach to global vehicle electrification. This investment adds capacity to support battery electric vehicles (BEV's) and plug-in hybrid electric vehicles (PHEV's). An additional eight BEV/PHEV battery production lines will be added to the two previously announced, for a total of ten battery lines. Production will be increased in a phased approach, with line launches planned through 2030 to reach a total production of more than 30GWh annually. said Sean Suggs, president of Toyota North Carolina. "Today's announcement reinforces Toyota's commitment to electrification and carbon reduction, bringing jobs and future economic growth to the region. We are excited to see the continued energy and support of this innovative manufacturing facility." [Source:PR Newswire] In 2021, Toyota, in partnership with Toyota Tsusho, announced the new Liberty location with an initial investment of $1.29 billion for battery production and the creation of 1,750 new jobs. With today's announcement, Toyota North Carolina solidifies its position as the company's epicenter of lithium-ion battery production in North America. Overall, the campus will boast seven million square feet, equating to 121 football fields of battery production. "Through the last few years of building relationships, including my most recent trip to Tokyo and meeting with President Sato, our partnership with Toyota has become stronger than ever, culminating in this historic announcement," said North Carolina Governor Roy Cooper. "North Carolina's transition to a clean energy economy is bringing better paying jobs that will support our families and communities for decades to come." A pioneer in electrified vehicles, Toyota has put more than 24.6 million hybrid, plug-in hybrid, fuel cell and battery electric vehicles on the road globally. By 2025, the company plans to have an electrified option available for every Toyota and Lexus model globally. The company is steadfast in its promise of being best-in-town by supporting local nonprofits and education initiatives. This year, Toyota announced donations totaling $200,000 to the Boys & Girls Clubs of Central Asheboro and Greensboro, Junior Achievement of the Triad, Shift_ed and Volunteer Center of the Triad. Last year, the company announced a $1 million investment in North Carolina students enrolled with Communities in Schools Randolph County and North Carolina Agricultural and Technical State University. Additional Quotes from North Carolina Officials "Toyota's latest expansion in North Carolina is monumental," said Senator Phil Berger. "The additional jobs and increased capital investment are proof that the Triad and our rural communities are prepared to support high-tech manufacturing. I'm thankful for Toyota's dedication to our state and I look forward to seeing it continue to grow and employ hard-working North Carolinians." House Speaker Tim Moore said, "Today's announcement that Toyota will make an additional investment of nearly $8 billion at its newest North American facility right here in North Carolina is a tribute to the hard work the General Assembly has done to ensure North Carolina is the best state for business and innovation." He continued, "Toyota's success is a prime example of how a balanced budget, a strong workforce, and a AAA credit rating pave the way for business growth. Toyota's additional investment in North Carolina is a sign that we are on the right track."

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Additive Manufacturing

Nexa3D Plans to Acquire Essentium for Broadened Capabilities

Nexa3D | November 07, 2023

Nexa3D, an ultrafast 3D printing leader, has taken a substantial step in staking its leader position in the industrial additive manufacturing space by signing a LOI to acquire Essentium, a manufacturer of HSE 3D printers and materials, adopted for high requirement, precision applications in aerospace, defense, and military. With this acquisition, Nexa3D will add high-speed extrusion (HSE) to its current product portfolio. The acquisition would broaden capabilities, diversify revenues, and expand addressable markets for the fast-growing 3D printing company. Avi Reichental, Co-founder, Chairman, and CEO of Nexa3D, stated that they are looking forward to welcoming the Essentium team to Nexa3D’s family. The acquisition will be a testament to their unwavering commitment to pushing the boundaries of 3D printing technology. He continued that by joining forces with Essentium, they aim to create synergies to deliver unmatched value to their customers. Together, they will drive ultrafast additive manufacturing innovation and provide even more powerful solutions for manufacturers seeking to achieve their production goals. Essentium, known for its variety of materials portfolio, true independent dual extruders (IDEX) and award-winning high-speed extrusion 3D printers, has provided solutions for complex polymer production applications 5 to 15 times quicker than other competing extrusion technologies. Essentium’s commitment to reliability and innovation has made it a go-to choice for manufacturers worldwide. Nexa3D has rapidly emerged as a leader in the 3D printing space, delivering excellent production solutions for businesses across various sectors. Best known for its ultrafast 3D printers, from desktops to the factory floor, its technology has redefined the possibilities of 3D printing production, enabling unparalleled productivity, material flexibility, and accuracy. Adopted by around 1200 customers all over the world, its printers have become the go-to solution for high-throughput production applications. This acquisition is expected to close by the end of this year or as soon as practicable afterward. Both Essentium and Nexa3D are committed to ensure a smooth transition and for maintaining uninterrupted services to existing and prospective customers. About Nexa3D Nexa3D is committed to the sustainable digitization of supply chains, driven by its relentless pursuit of advancing additive manufacturing. The company engineers ultrafast polymer 3D printers, capable of delivering remarkable productivity gains, up to 20 times greater, to professionals and businesses of varying sizes. Innovative partnerships with renowned material suppliers, combined with an open materials platform, serve as the catalyst for unlocking the full potential of additively manufactured polymers, particularly in volume production. Nexa3D leverages automated software tools, employing process interplay algorithms that optimize the production cycle.

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3D Printing

BizLink counts on Rapid Prototyping with the help of 3D printing technology

PR Newswire | November 03, 2023

BizLink, a leading provider of connectivity solutions worldwide, uses a method for creating physical prototypes with computer-aided design (CAD) data. This so called 'Rapid Prototyping' enables development times to be shortened, costs to be lowered and innovative ideas to be realised more quickly. BizLink's Automation & Drives business unit will showcase one of these solutions at the sps trade fair in Nuremberg, Southern Germany, which takes place from 14 to 16 November. In the development and production of individual injection moulded parts, a large part of the cost and time is spent on providing the appropriate tools. That is why BizLink uses Rapid Prototyping for sample parts in the development phase of overmoulded connection components. The principal objective of this technology involves testing and validating design concepts, functionality and features before there is any investment in series production. Through Rapid Prototyping, BizLink thus reduces development costs and time-to-market for overmoulded components and its reinforced innovative cable systems for factory automation. Rapid Prototyping involves applying layer upon layer of materials or bonding them to one another with 3D printing to make the desired object. This makes it possible to quickly adapt the design as changes can easily be made in the CAD data and the prototype can then be reprinted. It also allows, for example, the spatial conditions during fitting and operation under real-life conditions to be assessed, letting the findings thereby acquired be incorporated in product improvement before a tool-maker has even started his or her job. 3D printing technology can furthermore make valuable contributions to quality assurance while development is ongoing. If, for instance, parts being tested must be scrutinised to limit failure mechanisms along functional boundaries, it helps to be able to quickly create a matching testing device for such investigations. In some cases, such devices also facilitate good reproducibility, meaning that dependable component qualifications can also be carried out in this way. Other applications involve trialling numerous production resources and tools as well as handling aids that are, with respect to their function and ergonomics, initially tested as a 3D-printed specimen and improved repeatedly so that they can later be reproduced in a more robust version made of metal, for example. Rapid prototyping is versatile and has long been a proven tool for BizLink in the innovation process to bring new products to market faster and more effectively. Visitors to sps can convince themselves of these advantages through application examples in the Nuremberg exhibition halls from November 14 to 16, 2023 in Hall 2, Stand 431.

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Manufacturing Technology

Toyota Supercharges North Carolina Battery Plant with New $8 Billion Investment

PR Newswire | November 01, 2023

Toyota announced a new investment of nearly $8 billion that will add approximately 3,000 jobs at Toyota Battery Manufacturing North Carolina (TBMNC). This brings total investment to approximately $13.9 billion and job creation to more than 5,000 – further supporting Toyota's multi-pathway approach to global vehicle electrification. This investment adds capacity to support battery electric vehicles (BEV's) and plug-in hybrid electric vehicles (PHEV's). An additional eight BEV/PHEV battery production lines will be added to the two previously announced, for a total of ten battery lines. Production will be increased in a phased approach, with line launches planned through 2030 to reach a total production of more than 30GWh annually. said Sean Suggs, president of Toyota North Carolina. "Today's announcement reinforces Toyota's commitment to electrification and carbon reduction, bringing jobs and future economic growth to the region. We are excited to see the continued energy and support of this innovative manufacturing facility." [Source:PR Newswire] In 2021, Toyota, in partnership with Toyota Tsusho, announced the new Liberty location with an initial investment of $1.29 billion for battery production and the creation of 1,750 new jobs. With today's announcement, Toyota North Carolina solidifies its position as the company's epicenter of lithium-ion battery production in North America. Overall, the campus will boast seven million square feet, equating to 121 football fields of battery production. "Through the last few years of building relationships, including my most recent trip to Tokyo and meeting with President Sato, our partnership with Toyota has become stronger than ever, culminating in this historic announcement," said North Carolina Governor Roy Cooper. "North Carolina's transition to a clean energy economy is bringing better paying jobs that will support our families and communities for decades to come." A pioneer in electrified vehicles, Toyota has put more than 24.6 million hybrid, plug-in hybrid, fuel cell and battery electric vehicles on the road globally. By 2025, the company plans to have an electrified option available for every Toyota and Lexus model globally. The company is steadfast in its promise of being best-in-town by supporting local nonprofits and education initiatives. This year, Toyota announced donations totaling $200,000 to the Boys & Girls Clubs of Central Asheboro and Greensboro, Junior Achievement of the Triad, Shift_ed and Volunteer Center of the Triad. Last year, the company announced a $1 million investment in North Carolina students enrolled with Communities in Schools Randolph County and North Carolina Agricultural and Technical State University. Additional Quotes from North Carolina Officials "Toyota's latest expansion in North Carolina is monumental," said Senator Phil Berger. "The additional jobs and increased capital investment are proof that the Triad and our rural communities are prepared to support high-tech manufacturing. I'm thankful for Toyota's dedication to our state and I look forward to seeing it continue to grow and employ hard-working North Carolinians." House Speaker Tim Moore said, "Today's announcement that Toyota will make an additional investment of nearly $8 billion at its newest North American facility right here in North Carolina is a tribute to the hard work the General Assembly has done to ensure North Carolina is the best state for business and innovation." He continued, "Toyota's success is a prime example of how a balanced budget, a strong workforce, and a AAA credit rating pave the way for business growth. Toyota's additional investment in North Carolina is a sign that we are on the right track."

Read More

Additive Manufacturing

Nexa3D Plans to Acquire Essentium for Broadened Capabilities

Nexa3D | November 07, 2023

Nexa3D, an ultrafast 3D printing leader, has taken a substantial step in staking its leader position in the industrial additive manufacturing space by signing a LOI to acquire Essentium, a manufacturer of HSE 3D printers and materials, adopted for high requirement, precision applications in aerospace, defense, and military. With this acquisition, Nexa3D will add high-speed extrusion (HSE) to its current product portfolio. The acquisition would broaden capabilities, diversify revenues, and expand addressable markets for the fast-growing 3D printing company. Avi Reichental, Co-founder, Chairman, and CEO of Nexa3D, stated that they are looking forward to welcoming the Essentium team to Nexa3D’s family. The acquisition will be a testament to their unwavering commitment to pushing the boundaries of 3D printing technology. He continued that by joining forces with Essentium, they aim to create synergies to deliver unmatched value to their customers. Together, they will drive ultrafast additive manufacturing innovation and provide even more powerful solutions for manufacturers seeking to achieve their production goals. Essentium, known for its variety of materials portfolio, true independent dual extruders (IDEX) and award-winning high-speed extrusion 3D printers, has provided solutions for complex polymer production applications 5 to 15 times quicker than other competing extrusion technologies. Essentium’s commitment to reliability and innovation has made it a go-to choice for manufacturers worldwide. Nexa3D has rapidly emerged as a leader in the 3D printing space, delivering excellent production solutions for businesses across various sectors. Best known for its ultrafast 3D printers, from desktops to the factory floor, its technology has redefined the possibilities of 3D printing production, enabling unparalleled productivity, material flexibility, and accuracy. Adopted by around 1200 customers all over the world, its printers have become the go-to solution for high-throughput production applications. This acquisition is expected to close by the end of this year or as soon as practicable afterward. Both Essentium and Nexa3D are committed to ensure a smooth transition and for maintaining uninterrupted services to existing and prospective customers. About Nexa3D Nexa3D is committed to the sustainable digitization of supply chains, driven by its relentless pursuit of advancing additive manufacturing. The company engineers ultrafast polymer 3D printers, capable of delivering remarkable productivity gains, up to 20 times greater, to professionals and businesses of varying sizes. Innovative partnerships with renowned material suppliers, combined with an open materials platform, serve as the catalyst for unlocking the full potential of additively manufactured polymers, particularly in volume production. Nexa3D leverages automated software tools, employing process interplay algorithms that optimize the production cycle.

Read More

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