Future Challenges Complexity more materials, greater integration, personalisation,
Future Challenges Complexity more materials, greater integration, personalisation, increased use of biologics Maintaining or reducing costs automation, disruptive manufacturing approaches Building new business models retaining value in Europe New products and services - recognising
consumer demands before they do Advanced Manufacturing Processes Customisation Composite manufacture Manufacturing processes for renewable raw
materials, biomaterials and cell based products Joining technologies for advanced and multimaterials Delivery of new functionalities through (mass production) surface manufacturing
processes Manufacturing of flexible structures Product life cycle management for advanced materials What is Additive Manufacturing? (3D Printing)
The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies Rapid prototyping, noun additive manufacturing of a design, often iterative, for form, fit or functional testing or combination thereof.
Types of Aditive Manufacturing Vat Photopolymerization An additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerization. Stereolithography Envisiontec
Micro-SLA Material Jetting An additive manufacturing process in which droplets of build material are selectively deposited Wax or Photopolymers Multiple nozzles
Single nozzles Binder Jetting An additive manufacturing process in which a liquid bonding agent is selectively deposited to
join powder materials. Zcorp Voxeljet ProMetal/ExOne Material Extrusion An additive manufacturing process in
which material is selectively dispensed through a nozzle or orifice From microns to meters Stratasys FDM machines Office friendly DIY community Best selling platform
Powder Bed Fusion An additive manufacturing process in which thermal energy selectively fuses regions of a powder bed SLS, SLM, DMLS, EBM, etc. Polymers, metals & ceramics Sheet Lamination
An additive manufacturing process in which sheets of material are bonded to form an object. Paper (LOM) Using glue Plastic Using glue or heat
Metal Using welding or bolts Ultrasonic AM Directed Energy An additive manufacturing process Deposition in which focused
thermal energy is used to fuse materials by melting as they are being deposited Wire & Powder Materials Lasers & Electron Beams Great for feature addition & repair Medical imaging
Dentistry Paleontology Architecture and Design Morongo Casino, Palm
Springs, Model Entertainment Modeling Automotive Advanced Composite Process
Pultrusion Advance Joining Process Friction welding -Friction heat caused by the motion of one surface against another enables plastic deformation and atomic diffusion at the interface -Used by the automotive industry for decades in the
manufacture of a range of components -The weld is formed across the entire cross-sectional area of the interface in a single shot process Rotary Friction Welding Linear Friction Welding Friction stir welding Direct or continuous drive
Pre-determined time of motion determined by the size and type of material Linear friction welding 1-3mm Frequency 25125Hz
Maximum axial force 150kN Friction stir welding Advanvced Functional Material Process example nanomaterials 1. Top Down technique uses large
machines to make the nanostructures from larger materials Example: Photolithography to make Computer Processor Chips 2. Bottom Up technique uses chemical and physical interactions
to make nanostructures without guidance Example: Catalyst to make Carbon Nanotubes 3. Smart Materials are manufactured goods that react to some outside forces. Crystals can expand and contract with electricity, metals can
retain a shape memory, liquids can move with magnetic fields, and surface cracks can heal themselves. Processing of biomaterials
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