
Additive Manufacturing What is it?January 17th 2017
Additive Manufacturing (AM), also known as 3D printing, rapid prototyping or freeform fabrication is a process in which layers of material are used to form three dimensional objects under computer control; opposed to Subtractive Manufacturing such as machining.
Additive Manufacturing (AM), also known as 3D printing, rapid prototyping or freeform fabrication is a process in which layers of material are used to form three dimensional objects under computer control; opposed to Subtractive Manufacturing such as machining.
The use of AM with metal powders is a new and expanding industry, with the ability to now produce complex metal parts rather than just prototypes as before. This is enabling a design revolution in various sectors such as automotive, medical, tooling and energy among others. There are currently a wide range of metal powders being used in AM such as, Steels e.g. 316L, Nickel & Cobalt super alloys, titanium alloys & aluminium alloys. Many more powders are being developed including; copper alloys, magnesium alloys, precious metals and Tungsten alloys.
Using AM over more traditional production methods has the following benefits:
- Reduction in waste (Net shape process) – In standard aircraft manufacture up to 90% of material can be cut away
- Increased design freedom
- Possibility of lightweight structures e.g. lattice designs
- Potential for several parts to be constructed as one
- Reduced assembly operations e.g. welding
- Shorter production cycles
- No other tools needed e.g. molds
However this new technology also has several limitations:
- Only suitable for smaller parts up to 2-3kg
- Not yet suitable for mass production; the current capability for smaller parts is around 25,000 parts per year
- Design limitations – removable support structures can be required if an overhang is less than a 45° angle
- Material type – it is not yet possible to use non-wieldable metals in AM
- Porosity – can be some residual internal porosity
- Mechanical properties – the parts tend to be inferior to those which are wrought
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