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Applications of AM Processes - Coggle Diagram
Applications of AM Processes
Personalized Fabrication
(with personalized fabrication anything can be made depending on the process)
FDM
industrial equipment manufacturing
engine holder
Conceptual Parts
customized products
Fused Deposition Modelling (FDM) is a way in which a technology is used to dispose of filaments of thermal plastics, making sure that they are in a specific pattern. It allows the fabrication of durable components made of high strength thermoplastics. FDM is ideal because it is economical and does not require any chemical postprocessings.
Biomedical
FDM
Hearing Aids
Dental
Prosthetics
Organ Fabrications
the way that these products are going to be used is to help the people medically by allowing them to use the senses and parts of the body that they have unfortunately been taken away from them, which is a very amazing and beautiful creation that the 3D printers can do.
Digital Manufacturing
Wire Deposition
spring
fan blade
The wire deposition process, also known as wire and arc additive manufacturing (WAAM), uses a robot to deposit layers of molten metal from a wire through a welding head onto a surface.
the reason that wire deposition is good to use for these products is because the products ae required to have a nice finish and be what it required by the designer of the product to look like. It is a very good process to use as it has the process of layering up the materials that are used in the product to a very strong and sturdy product
Powder Bed
Powder bed fusion is the best for these products because it is cheap to use this process to make very big parts that can be very expensive to produce. there is also very little material waste which means that the cost of the products will be very low as well
Engine Part
robotic arm
Manufacture of aerospace and automotive components
Powder Bed
Tyre Moulds
Seat Belt Brackets
Injector Head
Brake Caliper
For each of these products powder bed fusion works by using a very common process of selective laser sintering and the selective laser sintering (SLS) process begins with the conversion of customer generated 3D CAD data into a sliced STL file using proprietary software. Once the file has been made then it is sent to the printer on the Selective Laser Sintering machine. The machine warms up (with LS material heated to just below melting point) before to the feed bed rises and the levelling roller pushes fresh powder across the build platform. The first layer is then traced out by a CO2 laser which melts and fuses the LS material upon contact. Once the first layer has completed the build platform the bed drops by a set amount. The feeder bed rises and a fresh layer of powder is swept along the build platform. The next layer is then traced out and the process repeats layer by layer until the model has completed. It is then left to cool and the leftover material is brushed away.
The powder bed fusion process is the best for these examples of products as they can all be made mostly in one piece and that can just make the product with a strong metal that is durable and reliable to complete the function that it has been made for.
FDM
the aerospace components are made mostly from FDM as it can produce the components very fast and they are lightweight and flexible which is perfect for aircraft vehicles.
Bezels - Dashboard Interface - Digital ABS
High strength to weight ratio
High thermal and chemical resistance
Rapid prototyping of products and components
FDM
FDM is used for rapid prototyping of products and components because FDM has the best process to make early concept prototypes, to validate designs and for the testing of certain specific properties for example heat resistance, durability and strength.
Gears
the way that gears are made from the process of FDM is by firstly designing the gears on fusion 360 and using an add-on called fusion 360 gear generator, then once the design has been made a file is sent to the 3D printing machine which then uses a spool of thermoplastic which then follows the design made in the 3D printing software, making sure that they are in a specific pattern. this allows the gear to be durable and have a high strength to weight ratio.
FDM rapid prototyping is a 3D printing process used for building prototype parts made from layers of ABS-M30 production-grade thermoplastic. The process normally includes the formation of a support structure which can be removed by hand when it is finished.
Tripods
Laser Sintering
A few examples of the products that are made from the process of laser sintering is products such as a tap
,
pipes
,
wine glasses or glass bottles
Selective laser sintering is an additive manufacturing (AM) technology that uses a high power laser to sinter small particles of polymer powder into a solid structure based on a 3D model. SLS 3D printing has been a popular choice for engineers and manufacturers for decades.an industrial 3D printing process that produces accurate - rapid prototypes and functional production parts in as fast as one day.
Within Laser Sintering there is also Selective Laser Sintering which is used for rapid prototyping of products such as the aerospace industry, in which SLS is used to build prototypes for airplane parts. It has the ability to change complex geometries in a very quick amount of time. The reason that it is the best AM process for rapid prototyping of products and components is because it is quicker than other processes such as FDM or SLA. It is also a better process as it has a better design freedom, which means when coming to the process of making the product there is no support structure needed for the product.
Moulds and Tooling
Laser Sintering
Tyre Moulds
Direct Metal Laser Sintering - DMLS is an additive technology that works by sintering very fine layers of metal powders layer-by-layer from the bottom up until the build is complete. The process begins by sintering a first layer of 20-micron powder onto a steel platform. The platform then lowers by 20 microns, a fresh layer of powder is swept over the previously sintered layer, and the next layer is sintered on top of the previously built one.
FDM
Near Net Shapes
Jigs
Patterns
Within FDM there is Sheet Metal Forming which is a type of process used to make engine components but in this case it can also be used to make jigs, near net shapes and patterns. Sheet Metal Forming is used by many industries because it offers a variety of benefits such as the reduced lead times and costs, design freedom and the ergonomic aspects, which helps the products that are being created to make sure that they are the best that they can be. FDM is the best choice of AM process to make jigs and the different patterns of moulds because it makes the product durable and strong and makes it have a high strength to weight ratio.
