Fundamentals of Additive Manufacturing for the Practitioner

Chapter 1 Introduction: Moving into Additive Manufacturing 1 Introduction 2 Manufacturing Processes 5 Traditional and AM Job Roles 8 Case Conclusion: Developing Knowledge and Skills in AM 15 How to Use This Book 16 References 19 Chapter 2 Is Additive Manufacturing the Right Solution? 21 Introduction 22 Additive Manufacturing Applications 23 AM Notable 1: 24 AM Notable 2: 33 A Brief History of AM 33 Selecting a Pilot AM Project 35 AM Notable 3: 38 Case Conclusion: Identifying AM Applications for a Pilot Project 39 References 41 Chapter 3 What Design and Inputs Does Additive Manufacturing Require? 43 Introduction 44 Design for AM 45 Design for DFAM 45 Component Design 47 AM Notable 3.1 50 Part Design 50AM Notable 3.2 54 Process Design 57 AM Notable 3.3 58 Sources of Input 58 AMF and STL File Formats 59 References 63 Chapter 4 What Materials Does Additive Manufacturing Use? 65 Introduction to AM Materials 66 Selecting AM Materials 67 Polymers 69 AM Notable 4.1 3D Printing a Ride to Mars 73 AM Notable 4.2 Chicken Feathers - Not Just for Pillows Anymore! 75 AM Notable 4.3 3D Print a House in 24 Hours for $10k (or less) 78 References 82 Chapter 5 Which Additive Manufacturing Technology and Process Are Right for My Solution? 85 Introduction 86 Binder Jetting 88 Directed Energy Deposition 90 Material Extrusion 92 Material Jetting 94 Powder Bed Fusion 96 Sheet Lamination 98 Vat Photopolymerization 99 Hybrid Systems 102 References 103 Chapter 6 What Machine and Build Preparation Occurs in Additive Manufacturing? 105 Introduction 106 AM Notable 6.1 106 General Machine and Build Preparation Tasks 107 AM Notable 6.2 111 AM Process-Specific Machine and Build Preparation 111 AM Notable 6.3 121 References 122 Chapter 7 What Occurs During the Additive Manufacturing Build Process? 123 Introduction 124 Quality in AM 124 Build Planning and the Build Process 128 Build Process 133 References 138 Chapter 8 What Happens after the Additive Manufacturing Build Process Is Complete? 141 Introduction 142 Part Removal 143 Material Removal 144 Support Removal 146 Treating 147 Finishing 147 Inspection 148 Summary of Post-Processing Methods 148 References 150 Chapter 9 What Do We Do to Move to Additive Manufacturing? 153 Introduction 153 AM Implementation Roadmap 154 Identify a Vision and Strategy 155 Prepare to Manage Change 157 Acquire AM Systems Access and Support 158 Develop AM Workflows 161 Develop Your AM Workforce 162 Monitor Results and Adjust 164 References 165 Chapter 10 Where Can I Learn More? 167 Introduction 167 AM Acronyms and Terminology 167 AM Job Postings and Employment Information 168 AM Education and Training 169 AM Professional Certification 170 AM Body of Knowledge (AMBOK) 170 AM University Consortia and Centers of Excellence 171 AM Service Bureaus and Vendors 171 AM Material Selection Guides 172 AM Technology Selection Guides 172 AM Design Guidelines 173 AM Professional Associations, Conferences, and Meetings 173 Index 175