Which Additive Manufacturing Process Is Right for You?

Bhagyashri Kambale | December 06, 2021 | 2205 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

Spotlight

Cadillac

At Cadillac, we believe that only those who dare drive the world forward. Follow us as we celebrate achievement, champion innovation, and encourage the pursuit of unwavering passion. We’ve embarked on a bold new journey; now’s the time to join us.

OTHER ARTICLES

Achieving Interoperability in an Industry 4.0 Factory

Article | February 11, 2020

As a part of the Industry 4.0 movement, factory engineers are increasingly adopting some form of industrial Ethernet to interconnect the machines and other equipment implementing their production processes. Ethernet has been around in multiple forms for over 40 years. Most of it serves the IT community by interconnecting PCs and other equipment to a company LAN. Because of its flexibility, Ethernet has been adapted to many industrial uses.

Read More

The Impact of Coronavirus on Electronic Manufacturing

Article | February 11, 2020

Wuhan, the epicenter of the outbreak, is considered a crucial hub in the middle of China, a place of high importance for the production of automobiles, electronics, optics, and fiber optics. Wuhan and surrounding cities in the Hubei province are currently on a government-imposed quarantine at a scale the world has never seen before, some Chinese officials have referred to the situation as warlike.

Read More

Digitalizing Your Manufacturing Ecosystem

Article | February 10, 2020

Making digitalization work for you requires an understanding of your manufacturing ecosystem. Standards - such as ISA-95 - only guide you on a journey to more deeply comprehend the workings of your unique process for manufacturing your products. A batch manufacturing ecosystem often includes campaign management. Campaign management is not mentioned in ISA-95, which only speaks generally of order processing.

Read More

4 Food and Beverage Manufacturing Trends on Tap for 2020

Article | February 10, 2020

It’s the food and beverage industry’s job to appeal to consumer tastes by keeping tabs on what’s hot and what’s not. In the 1990s, for instance, fat free or reduced fat was all the rage, evidenced by the variety of products with such descriptions featured in bold typeface on cartons, cardboard and boxes. Fast forward to today, thanks in part to advancements in nutrition science, fat is back and is recommended in low-carb diets such as Atkins and Keto.

Read More

Spotlight

Cadillac

At Cadillac, we believe that only those who dare drive the world forward. Follow us as we celebrate achievement, champion innovation, and encourage the pursuit of unwavering passion. We’ve embarked on a bold new journey; now’s the time to join us.

Related News

MANUFACTURING TECHNOLOGY

Infinite Electronics, Inc., Announces the Acquisition of Bulgin

Infinite Electronics, Inc. | January 20, 2023

On January 19, 2023, Infinite Electronics, Inc., the leading global supplier of electronic components, announced the acquisition of Bulgin Ltd, a UK-based developer and manufacturer of connectors and related components for harsh-environment applications. Equistone Partners Europe, a renowned European mid-market private equity firm, was the previous owner of Bulgin. Bulgin has over a century of expertise designing, developing, and producing IP66, IP67, IP68, and IP69K severe environment connectivity solutions for customers in various industries. Bulgin is focused on bespoke services and custom capabilities, as well as fast prototyping and a Rapid Response Team (RRT) to meet customers' urgent needs. Since Equistone acquired the company in 2019, Bulgin has expanded dramatically, opening a new site in Tunis, Tunisia, as well as new headquarters in Cambridge, UK. Bulgin has over 600 distributor locations across 60 countries and six continents. It employs 680 people worldwide, including its headquarters in the United Kingdom, businesses in Tunisia and Santa Fe Springs, California, as well as a foothold in the Asia-Pacific region. This acquisition expands Infinite Electronics' presence in Europe. It follows the company's announcement of entering a definitive agreement to acquire Cable Connectivity Group (CCG) from Torqx Capital Partners and TKH Group NV, a leading producer and distributor of specialty cables and cable connectivity solutions. These acquisitions are prominent milestones in Infinite Electronics' six-year rapid growth. These slew of acquisitions are the latest milestones in Infinite Electronics' aggressive expansion over the last six years. About Infinite Electronics, Inc. Based in Irvine, California, Infinite Electronics is a leading global electrical component supplier, meeting engineers' urgent needs through a family of well-known and trusted brands. It offers a diverse range of components, assemblies, and wired/wireless connectivity solutions and serves the aerospace/defense, industrial, government, consumer electronics, instrumentation, medical and telecommunications markets. Infinite's brands include Pasternack, Fairview Microwave, L-com, MilesTek, Aiconics, KP Performance Antennas, PolyPhaser, Transtector, RadioWaves, ShowMe Cables, Integra Optics, INC Installs and NavePoint. By working quickly to supply goods, solutions, and real-time support to its clients, its brands help move the world's innovators forward.

Read More

MANUFACTURING TECHNOLOGY

Helios Technologies to Acquire Schultes Precision Manufacturing

Helios Technologies, Inc. | January 19, 2023

Helios Technologies, Inc., a global technology leader in the hydraulics and electronics markets, has signed a definitive agreement to acquire Schultes Precision Manufacturing, Inc. Schultes, a precision machined components and assemblies manufacturer for customers with extremely tight tolerances, excellent quality, and exceptional value-added manufacturing process requirements. Schultes consistently delivers manufacturing quality, reliability, and responsiveness crucial to its customers' success and is currently serving the communication, hydraulic, aerospace, food services, medical devices, and dental industries. Schultes acquisition will help Helios move into new end markets with complementary manufacturing expertise and favorable secular tailwinds. It will also open new avenues into communication, food services, communication, as well as the life sciences sector, including those for medical devices and dental applications. As a strategic partner, Schultes, gives Helios more depth in manufacturing processes which can be used to expand its "in the region for the region" strategy. In 2022, Schultes had roughly $30 million in revenue, and currently operates from its newly expanded 110,000 square foot facility based on seven acres with roughly 20,000 square feet of additional space for future growth. In addition, Schultes provides rapid growth applications to its customers, from prototype to full-rate production. Josef Matosevic, Helios’ President and Chief Executive Officer, said, “Schultes is an excellent bolt-on flywheel acquisition to add to our Hydraulics segment. It brings process technology and know-how that advances our ability to serve our customers with a broader product and solutions portfolio.” He further added, “It also expands and diversifies our markets and continues to optimize our manufacturing and operating footprint. Schultes is yet another strong standalone business with a healthy margin profile that fits perfectly into our Hydraulics business. This transaction is another milestone that further validates that we are making great progress against our augmented strategy and long-term goals.” (Source – Businesswire) Helios expects the acquisition to be completed in the first quarter of 2023, subjected to customary closing conditions. The terms were not disclosed. About Helios Technologies, Inc. Helios Technologies is a leading motion control and electronic controls technology provider for a wide range of end markets, such as agriculture, construction, energy, material handling, recreational vehicles, maritime, and health and wellness. It develops and manufactures innovative products and solutions, including customized electronic control systems, hydraulic cartridge valves and quick-release couplings. Helios' products are sold to customers in over 90 countries worldwide. The company's growth plan is to be the leading provider of premier products and solutions in niche areas through innovative product creation and acquisition.

Read More

DIGITAL TRANSFORMATION

Viridi Parente Chooses Bright Machines to Digitize Manufacturing Facility

Bright Machines | January 25, 2023

On January 24, 2023, Bright Machines, a leader in intelligent, software-defined manufacturing, and Viridi Parente, Inc., a leading developer of safe, resilient, point-of-use battery storage technology, announced that Viridi has chosen Bright Machines to transform the company's U.S. electric battery manufacturing facility digitally. Bright Machines Microfactories, the company's full-stack assembly automation solution, modernizes production by integrating data and AI. This gives Viridi new capability to fulfill the growing demand for its zero-carbon emission energy battery solutions. Viridi manufactures battery energy storage systems in Buffalo, New York. Bright Machines will play a key role in the assembly of Viridi's stationary lithium-ion battery pack system modules, which are developed and tested to be fail-safe for installation in industrial, commercial, and residential settings. Companies like Viridi and Bright Machines are fueling the United States' re-emergence as a global manufacturing powerhouse. Bright Machines will assist Viridi in automating the assembly of its clean, sustainable power sources, which will replace century-old distributed energy platforms, including fossil fuel, lead-acid batteries, and other outmoded technologies. Additionally, Viridi will implement more sustainable practices by utilizing Bright Machines' intelligent automation solution, which evaluates production areas to determine the appropriate material requirements to reduce fault rates. Viridi will also be able to decrease overproduction and instead produce-to-order depending on local market demand as its facility is near the end consumer. This will result in reduced landfill and an overall reduction in Viridi's carbon footprint. The only option to reduce costs, emissions, and geopolitical risks while satisfying U.S. battery and electrification demand is to localize the production of crucial battery components. Intelligent assembly automation from Bright Machines enables rapid product evolution at a low cost while minimizing time to market. In addition, the trend toward closer-to-home production promotes jobs in the United States and allows businesses to progress their sustainability efforts through local and regional supply chains. About Bright Machines Founded in 2018, Bright Machines is a leading technology firm that offers an innovative approach to software-defined, intelligent manufacturing. It uses machine learning, computer vision, 3D simulation, and adaptive robotics to alter production's flexibility, scalability, and economics fundamentally. Bright Machines runs R&D facilities in the United States and Israel, with additional field operations in the United States, Mexico, China, and Poland, and it employs more than 500 people globally. It has been recognized as a "Technology Pioneer" by the World Economic Forum and one of "America's Most Promising Artificial Intelligence Companies" by Forbes in 2019.

Read More

MANUFACTURING TECHNOLOGY

Infinite Electronics, Inc., Announces the Acquisition of Bulgin

Infinite Electronics, Inc. | January 20, 2023

On January 19, 2023, Infinite Electronics, Inc., the leading global supplier of electronic components, announced the acquisition of Bulgin Ltd, a UK-based developer and manufacturer of connectors and related components for harsh-environment applications. Equistone Partners Europe, a renowned European mid-market private equity firm, was the previous owner of Bulgin. Bulgin has over a century of expertise designing, developing, and producing IP66, IP67, IP68, and IP69K severe environment connectivity solutions for customers in various industries. Bulgin is focused on bespoke services and custom capabilities, as well as fast prototyping and a Rapid Response Team (RRT) to meet customers' urgent needs. Since Equistone acquired the company in 2019, Bulgin has expanded dramatically, opening a new site in Tunis, Tunisia, as well as new headquarters in Cambridge, UK. Bulgin has over 600 distributor locations across 60 countries and six continents. It employs 680 people worldwide, including its headquarters in the United Kingdom, businesses in Tunisia and Santa Fe Springs, California, as well as a foothold in the Asia-Pacific region. This acquisition expands Infinite Electronics' presence in Europe. It follows the company's announcement of entering a definitive agreement to acquire Cable Connectivity Group (CCG) from Torqx Capital Partners and TKH Group NV, a leading producer and distributor of specialty cables and cable connectivity solutions. These acquisitions are prominent milestones in Infinite Electronics' six-year rapid growth. These slew of acquisitions are the latest milestones in Infinite Electronics' aggressive expansion over the last six years. About Infinite Electronics, Inc. Based in Irvine, California, Infinite Electronics is a leading global electrical component supplier, meeting engineers' urgent needs through a family of well-known and trusted brands. It offers a diverse range of components, assemblies, and wired/wireless connectivity solutions and serves the aerospace/defense, industrial, government, consumer electronics, instrumentation, medical and telecommunications markets. Infinite's brands include Pasternack, Fairview Microwave, L-com, MilesTek, Aiconics, KP Performance Antennas, PolyPhaser, Transtector, RadioWaves, ShowMe Cables, Integra Optics, INC Installs and NavePoint. By working quickly to supply goods, solutions, and real-time support to its clients, its brands help move the world's innovators forward.

Read More

MANUFACTURING TECHNOLOGY

Helios Technologies to Acquire Schultes Precision Manufacturing

Helios Technologies, Inc. | January 19, 2023

Helios Technologies, Inc., a global technology leader in the hydraulics and electronics markets, has signed a definitive agreement to acquire Schultes Precision Manufacturing, Inc. Schultes, a precision machined components and assemblies manufacturer for customers with extremely tight tolerances, excellent quality, and exceptional value-added manufacturing process requirements. Schultes consistently delivers manufacturing quality, reliability, and responsiveness crucial to its customers' success and is currently serving the communication, hydraulic, aerospace, food services, medical devices, and dental industries. Schultes acquisition will help Helios move into new end markets with complementary manufacturing expertise and favorable secular tailwinds. It will also open new avenues into communication, food services, communication, as well as the life sciences sector, including those for medical devices and dental applications. As a strategic partner, Schultes, gives Helios more depth in manufacturing processes which can be used to expand its "in the region for the region" strategy. In 2022, Schultes had roughly $30 million in revenue, and currently operates from its newly expanded 110,000 square foot facility based on seven acres with roughly 20,000 square feet of additional space for future growth. In addition, Schultes provides rapid growth applications to its customers, from prototype to full-rate production. Josef Matosevic, Helios’ President and Chief Executive Officer, said, “Schultes is an excellent bolt-on flywheel acquisition to add to our Hydraulics segment. It brings process technology and know-how that advances our ability to serve our customers with a broader product and solutions portfolio.” He further added, “It also expands and diversifies our markets and continues to optimize our manufacturing and operating footprint. Schultes is yet another strong standalone business with a healthy margin profile that fits perfectly into our Hydraulics business. This transaction is another milestone that further validates that we are making great progress against our augmented strategy and long-term goals.” (Source – Businesswire) Helios expects the acquisition to be completed in the first quarter of 2023, subjected to customary closing conditions. The terms were not disclosed. About Helios Technologies, Inc. Helios Technologies is a leading motion control and electronic controls technology provider for a wide range of end markets, such as agriculture, construction, energy, material handling, recreational vehicles, maritime, and health and wellness. It develops and manufactures innovative products and solutions, including customized electronic control systems, hydraulic cartridge valves and quick-release couplings. Helios' products are sold to customers in over 90 countries worldwide. The company's growth plan is to be the leading provider of premier products and solutions in niche areas through innovative product creation and acquisition.

Read More

DIGITAL TRANSFORMATION

Viridi Parente Chooses Bright Machines to Digitize Manufacturing Facility

Bright Machines | January 25, 2023

On January 24, 2023, Bright Machines, a leader in intelligent, software-defined manufacturing, and Viridi Parente, Inc., a leading developer of safe, resilient, point-of-use battery storage technology, announced that Viridi has chosen Bright Machines to transform the company's U.S. electric battery manufacturing facility digitally. Bright Machines Microfactories, the company's full-stack assembly automation solution, modernizes production by integrating data and AI. This gives Viridi new capability to fulfill the growing demand for its zero-carbon emission energy battery solutions. Viridi manufactures battery energy storage systems in Buffalo, New York. Bright Machines will play a key role in the assembly of Viridi's stationary lithium-ion battery pack system modules, which are developed and tested to be fail-safe for installation in industrial, commercial, and residential settings. Companies like Viridi and Bright Machines are fueling the United States' re-emergence as a global manufacturing powerhouse. Bright Machines will assist Viridi in automating the assembly of its clean, sustainable power sources, which will replace century-old distributed energy platforms, including fossil fuel, lead-acid batteries, and other outmoded technologies. Additionally, Viridi will implement more sustainable practices by utilizing Bright Machines' intelligent automation solution, which evaluates production areas to determine the appropriate material requirements to reduce fault rates. Viridi will also be able to decrease overproduction and instead produce-to-order depending on local market demand as its facility is near the end consumer. This will result in reduced landfill and an overall reduction in Viridi's carbon footprint. The only option to reduce costs, emissions, and geopolitical risks while satisfying U.S. battery and electrification demand is to localize the production of crucial battery components. Intelligent assembly automation from Bright Machines enables rapid product evolution at a low cost while minimizing time to market. In addition, the trend toward closer-to-home production promotes jobs in the United States and allows businesses to progress their sustainability efforts through local and regional supply chains. About Bright Machines Founded in 2018, Bright Machines is a leading technology firm that offers an innovative approach to software-defined, intelligent manufacturing. It uses machine learning, computer vision, 3D simulation, and adaptive robotics to alter production's flexibility, scalability, and economics fundamentally. Bright Machines runs R&D facilities in the United States and Israel, with additional field operations in the United States, Mexico, China, and Poland, and it employs more than 500 people globally. It has been recognized as a "Technology Pioneer" by the World Economic Forum and one of "America's Most Promising Artificial Intelligence Companies" by Forbes in 2019.

Read More

Events