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Which Additive Manufacturing Process Is Right for You?

Bhagyashri Kambale | December 06, 2021 | 1545 views
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

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Amnovis Selects 3D Systems’ Dual Laser Direct Metal Printing Solution to Advance High-Reliability Applications

3D Systems | October 06, 2022

3D Systems (NYSE:DDD) announced that Amnovis, an additive manufacturing production and engineering company based in Aarschot, Belgium, has incorporated 3D Systems’ DMP Flex 350 Dual into its contract manufacturing workflow. This next-generation technology includes two lasers, which enables Amnovis to produce high-quality, highly reliable end-use parts for a variety of industrial and medical device applications. As a result of employing the DMP Flex 350 Dual solution, Amnovis is realizing enhanced productivity – at least 50% more as compared to the single laser DMP Flex 350 – and lower costs. Amnovis’ founders were among the first to employ laser powder bed fusion (LPBF) technology to additively manufacture Titanium medical devices such as orthopedic and spinal implants. Incorporating the DMP Flex 350 Dual printer into its manufacturing workflow is allowing Amnovis to expand its potential for stock and patient-specific medical device innovation. This unique innovation ecosystem is also enabling Amnovis to introduce product and process enhancements that can also be utilized for highly regulated industrial applications including aerospace and high tech. The DMP Flex 350 Dual is the most recent addition to 3D Systems’ Direct Metal Printing (DMP) portfolio. This dual-laser configuration maintains the benefits of the single-laser configuration including flexible application use and quick-swap build modules, and a central server to manage print jobs, materials, settings, and maintenance for 24/7 productivity. Additionally, the company’s unique vacuum chamber significantly reduces argon gas consumption while delivering best-in-class oxygen purity (<30 ppm). The printer also includes Oqton’s 3DXpert — the all-in-one software for industrial additive manufacturing that enables efficient preparation, optimization, and 3D printing of high-quality parts by streamlining the workflow from design to printing. The DMP Flex 350 Dual is designed to help accelerate innovation for a variety of applications including medical devices, aerospace, turbomachinery, semiconductors, and automotive & motorsports. “For us, innovation benefits from material and process enhancements, as well as the ability to increase productivity, We’ve experienced a tremendous leap in 3D printing efficiency by integrating 3D Systems’ DMP Flex 350 Dual into our workflow. By scaling our high-end parts manufacturing for quality-critical applications in medical, high tech, and other industries, we ensure faster delivery at lower cost, while maintaining our high-quality standards." -Ruben Wauthle, CEO and co-founder, Amnovis. In order for our service bureau customers to gain a competitive advantage, they need to differentiate the services they provide while becoming increasingly responsive to customer requirements, said Scott Anderson, vice president, segment leader, 3D Systems. Our collaboration with Amnovis is yet another example of how we can apply our application development expertise and a broad range of integrated additive manufacturing solutions to help maximize productivity, reliability, uptime, and yield. By integrating the DMP Flex 350 Dual into its solution portfolio, Amnovis is delivering high-quality parts to their customers while realizing exceptional total cost of ownership. About 3D Systems: More than 35 years ago, 3D Systems brought the innovation of 3D printing to the manufacturing industry. Today, as the leading additive manufacturing solutions partner, we bring innovation, performance, and reliability to every interaction - empowering our customers to create products and business models never before possible. Thanks to our unique offering of hardware, software, materials, and services, each application-specific solution is powered by the expertise of our application engineers who collaborate with customers to transform how they deliver their products and services. 3D Systems’ solutions address a variety of advanced applications in healthcare and industrial markets such as medical and dental, aerospace & defense, automotive, and durable goods. About Amnovis: Amnovis, based in Aarschot, Belgium, is a manufacturing and engineering company that uses innovative additive manufacturing (AM) technologies and materials for high-end applications such as medical devices. As an ISO 13485 certified contract manufacturer, Amnovis offers best-in-class AM technologies and expertise and paves the way for emerging AM technologies and materials. Digital process automation provides the traceability and repeatability to flexibly scale up manufacturing of products that comply with customer and regulatory requirements.

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MANUFACTURING TECHNOLOGY

SANMINA AND RELIANCE COMPLETE PREVIOUSLY ANNOUNCED MANUFACTURING JOINT VENTURE TRANSACTION IN INDIA

Sanmina | October 04, 2022

Sanmina Corporation (Sanmina) (NASDAQ: SANM), a leading integrated manufacturing solutions company and Reliance Strategic Business Ventures Limited (RSBVL), a wholly-owned subsidiary of Reliance Industries Limited (RIL), India's largest private sector company, today announced they have completed the previously announced joint venture transaction. This partnership will leverage Sanmina's 40 years of advanced manufacturing experience and Reliance's expertise and leadership in the Indian business ecosystem. The day-to-day business will continue to be managed by Sanmina's management team in Chennai, which will be seamless from an employee and customer perspective. The joint venture will create a world-class electronic manufacturing hub in India, in line with the Hon'ble Prime Minister's "Make in India" vision. The joint venture will prioritize high technology infrastructure hardware, for growth markets, and across industries such as communications networking (5G, cloud infrastructure, hyperscale datacenters), medical and healthcare systems, industrial and cleantech, and defense and aerospace. In addition to supporting Sanmina's current customer base, the joint venture will create a state-of-the-art 'Manufacturing Technology Center of Excellence' that will serve as an incubation center to support the product development and hardware start-up ecosystem in India, as well as promote research and innovation of leading-edge technologies. All the manufacturing will take place at Sanmina's 100-acre campus in Chennai, with the ability for site expansion to support future growth opportunities as well as to potentially expand to new manufacturing sites in India over time based on business needs. About Sanmina: Sanmina Corporation is a leading integrated manufacturing solutions provider serving the fastest growing segments of the global Electronics Manufacturing Services (EMS) market. Recognized as a technology leader, Sanmina provides end-to-end manufacturing solutions, delivering superior quality and support to Original Equipment Manufacturers (OEMs) primarily in the communications networks, cloud solutions, industrial, defense, medical and automotive markets. Sanmina has facilities strategically located in key regions throughout the world. About Reliance Strategic Business Ventures Limited (RSBVL): RSBVL is a wholly-owned subsidiary of Reliance Industries Limited. The principal activities of RSBVL are trading of goods and holding strategic interests in businesses and providing business support services. RSBVL had a revenue of INR 1,478.1 crore ($194.9 million), net profit of INR 179.8 crore ($23.6 million) for the year ended March 31, 2022 and had total investment of INR 10,857.7 crore ($1.4 billion) as of March 31, 2022. About Reliance Industries Limited (RIL): Reliance is India's largest private sector company, with a consolidated revenue of INR 792,756 crore ($104.6 billion), cash profit of INR 110,778 crore ($14.6 billion), and net profit of INR 67,845 crore ($9.0 billion) for the year ended March 31, 2022. Reliance's activities span hydrocarbon exploration and production, petroleum refining and marketing, petrochemicals, renewables (solar and hydrogen), retail and digital services.

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MANUFACTURING TECHNOLOGY

Epicor Acquires MES Provider eFlex Systems, Expanding Industry 4.0 Capabilities to Modernize Manufacturing Production Processes

Epicor | October 07, 2022

Epicor, a global leader of industry-specific enterprise software to promote business growth, today announced it has acquired eFlex Systems, a provider of cloud-based Manufacturing Execution System (MES) technologies. The acquisition expands the Epicor portfolio of Advanced MES capabilities to help manufacturers increase productivity by modernizing their production environments through digital work instructions, advanced process control, and real-time visibility. Financial terms were not disclosed. “I am thrilled to bring eFlex Systems into the Epicor family! Shop floors are a complex intersection of people, machines, robots, and materials, and it’s critical they work seamlessly together, People will continue to be at the heart of manufacturing, and our acquisition of eFlex Systems extends our ability to give Epicor customers the information they need to improve the user experience and unlock new levels of productivity.” -Steve Murphy, CEO Epicor. The eFlex Systems Manufacturing Integrated Platform (MIP®) enables manufacturers to manage and visualize global operations in real time, connecting devices, sensors, and machines with people to help operators build the right part, with the right tool, at the right setting in a safe and repeatable way. This helps manufacturers solve labor challenges by simplifying tasks and extending workers with connected devices which improves productivity. Epicor customers will be able to digitize processes through operator guidance, alerts, traceability, and data collection at the individual task level. Workstations can be configured and connected to their environments through open protocols and tools such as RFID, MQTT, and Node-RED, enabling operators to seamlessly leverage IoT devices such as DC tooling, barcode readers, weight scales, pick lights, PLCs, and others to complete the task at hand. “We’ve always been focused at eFlex Systems on helping customers reimagine manufacturing through sustainable, world-class production processes, By joining with Epicor, we’re furthering our mission to modernize manufacturing and bridge the data gap with cost-effective, easy-to-use solutions that drive efficiencies and throughput.” -Dan McKiernan CEO eFlex. About Epicor: Epicor Software Corporation equips hard-working businesses with enterprise solutions that keep the world turning. For nearly 50 years, Epicor customers in the automotive, building supply, distribution, manufacturing, and retail industries have trusted Epicor to help them do business better. Innovative Epicor solution sets are carefully curated to fit customer needs and built to respond flexibly to their fast-changing reality. With deep industry knowledge and experience, Epicor accelerates its customers’ ambitions, whether to grow and transform, or simply become more productive and effective.

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