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Addititve Manufacturing (Diffrent methods (7) (1 Binder Jetting, a liquid…
Addititve Manufacturing
Market, in order of mostly used.
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Medicinal
Implants, dental, tools. Third largets sector.
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Tooling
Injection moulding, die casting, tool repair.
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Diffrent methods (7)
1 Binder Jetting, a liquid bonding agent is selectively deposited to join powder particles - Metals, polymers and ceramics. Layer of powder is spread by an automated roller and print heads apply a liquid binder and color simultaneously to create a cross section of the built component obeject on the powder layer.
3D printing of sand moulds.
- Directed energy deposition, focused thermal energy is used to fuse materials by melting as they are being deposited.
- Metal powder and wire.
- Complex printing process used to repair or add additional material to existing surface. End-use with low structural property requierments.
- Material extursion, material (thermoplastic filament) is selectively despensed through a nozzel. One method is FDM.
- Polymer
- FDM (process in which plastic or wax material is extruded through a heated nozzle and form a cross-seciton of the component layer by layer.)
- 3D objects with low structural requierments. Tooling, light and modular structures (hollow spheres)
- Material jetting, droplets of the build material are selectivly deposited.
- photopolymer and wax
- drops of liquid are jetted on the build tray and UV light is than used to solidify the layers.
- Multi-material printing - multiply jets.
- Marketing prototypes with colour, automotive covers/trim kits/dashboards.
- Powder bed fusion, thermal energy selectivly fuses regions of a powder bed.
- Metal, polymer and ceramic powder.
- Most growing technique, but still small, 2500 total.
- Laser or electron beam is used to melt and fuse material powder togheter layer by layer. SLM/EBM
SLM - requires protective gas, larger built place. Metals and polymers. finer powder is used. Higher productivity by using multiple lasers simultaneously. Powder recyclability.EBM - requires vacuum, only for metals and alloys. Robust processing, for biomedical and aerospace stuff, low number of materials aviable. Powder bed "pre sintering", lowers recycleability of the powder, restrics possibilty to produce small channels.
- Typically requires post-treatment. To relieve residual stresses and minimize number of defects.
- Sheet lamination, sheets of material are bonded to form an object.
- Metal, hybrids, ceramic and paper.
UAM - sheets of metal are bound togheter using ultrasonic welding. Can bond diffrent materials and requires additional machiningLOM - paper is used and layers are bonded by adhesive material. Objects can be used as visual models
- Larger parts, tooling, non structural parts.
- Vat photopolymerization. Liquid photopolymer in a vat is selectivly cured by light-activated polymerization.
- Photopolymer and ceramic.
Model is constructed from the vat of liquied photopolymer resin layer by layer. Resin is hardened by an UV light where needed, and object moves downwards after each layer being cured. Model is build in liquid so there is no need for structural support.
- Mostly prototypes for fit, form and functionality.
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Sintering
The metallurgical bonding of particles in a powder mass or compact resulting from a thermal treatment at a tempature below the melting point of the main constituent.
Preheat, delube or burn off zone
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Typical Press and Sinter products:
- Gears, sprockets, cams rachets, levers, clutch platse, pressure plates, housings.
Typical Markets:
- Automotive, appliances, power tools.
MIM Technology for producing complex shape parts in high quantaties.
- Much more expensive than conventional pressing and sintering.
- If a lot of complex part is needed, MIM is cheaper than machining.
- Small precision components
- Both large and small volumes
- Complex shapes.
- Almost all materials.
GAS ATOMIZED powder only!!!
Hard Materials A group of sintered hard wear resistant composite materials, which consists of hard carbide particles bonded togheter by a metallic binder.
- The hard phase is usually carbides of W (dominant) Ta, Ti and V. Fraction of the carbide phase is between 70 to 97% of the total weight.
- Hard phases are bonded by metal with lower melting point - usually Co-based alloys.