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Additive Manufacturing Engineering
Including stereolithography technology (SLA), laminated solid manufacturing technology (LOM), fused deposition modeling technology (FDM), selective laser sintering technology (SLS), selective laser melting technology (SLM), and electron beam selective melting technology (EBSM) , Laser Engineering Net Shaping Technology (LENS), etc.
Edited at 2024-12-10 22:29:44
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Additive Manufacturing Engineering
- 稲盛和夫氏 私の今世の経験は、全部をまとめると、この36つだけです！
これは稲盛和夫に関するマインドマップです。私のこれまでの人生のすべての経験は、ビジネスの明確な目的と意味、強い意志、売上の最大化、業務の最小化、そして運営は強い意志に依存することを主な内容としています。
- 計画テンプレート - 月次計画ボード
かんばんボードのデザインはシンプルかつ明確で、計画が一目で明確になります。毎日の進捗状況を簡単に記録し、月末に要約を作成して成長と成果を確認することができます。 実用性が高い：読書、早起き、運動など、さまざまなプランをカバーします。 操作簡単：シンプルなデザイン、便利な記録、いつでも進捗状況を確認できます。 明確な概要: 毎月の概要により、成長を明確に確認できます。 小さい まとめ、今月の振り返り掲示板、今月の習慣掲示板、今月のまとめ掲示板。
- 計画テンプレート - 年間計画
2025 年度計画テンプレートは、1 年間の開発を包括的に計画するためのツールであり、今後の方向性を示すことができます。このテンプレートでは、夢の実現に向けた取り組みに役立つ、年間目標の設定、四半期目標の内訳、月次計画の策定について詳しく説明しています。
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- Outline
Additive Manufacturing Engineering
Stereolithography (SLA)
principle
Process principle: Use light energy to solidify liquid resin materials, control the shape of the light energy to solidify the resin layer by layer, and stack it into the required three-dimensional solid parts.
Exposure method
surface exposure
Blackout mask method
Digital light processing technology (DLP projection method)
Liquid crystal display (LCD)
point exposure
Stereolithography (SLA)
Common scanning methods
X.Y axis scanning method: large molding range, slow speed
Galvanometer scanning method: small molding range, fast speed, high cost
Material
Element
Photoinitiator: absorbs ultraviolet light energy and initiates polymerization reaction
Oligomers: The bulk of the material, which determines its properties after curing
Diluting the monomer: adjusting the viscosity, also participating in the curing reaction, affecting the performance of the cured film
Cured film is each layer of cured material
Other materials: added according to different uses
Whether it can be formed, that is, the shape and dimensional accuracy after forming
Nature requirements
Stable performance before curing, no polymerization reaction occurs under visible light
low viscosity
Good photosensitivity
Small curing shrinkage
After curing, it has high mechanical strength, corrosion resistance and good thermal stability.
Low toxicity
Classification
Free radical photocurable resin
Cationic photocurable resin
Hybrid photosensitive resin
Functional photosensitive resin
System hardware composition
Laser (320nm-370nm)
Optical system
Scanning irradiation system
Layered overlay solidification molding system
Equipment composition
Laser and galvanometer systems
Platform lifting system (screw drive)
Liquid storage tank and resin processing system
control system
process
light path
environment
Resin spreading system (squeegee)
Laminated solid manufacturing technology (LOM)
Craftsmanship
Principle: Sheets are cut layer by layer and then stacked and formed.
Due to limited materials, there are currently few applications
Coating process
Coating shape
Uniform type: using slit scraper
Non-uniform type (can reduce stress concentration, but the equipment is more expensive)
stripe
particles
Coating thickness: as thin as possible while ensuring bonding strength
Material
paper material
Body: moisture resistance, good wettability, tensile strength, shrinkage, good peeling performance, easy to polish, smooth surface, stable
hot melt glue
Good hot melt cooling properties
Maintains good physical and chemical stability under repeated melting and solidification conditions
In the molten state, it has good coating and evenness with paper materials.
Sufficient bonding strength to paper
Good waste separation
plastic film
metal foil
equipment
Mechanical system: multi-axis small laser processing system
Body: installation, fixed actuator
laser scanning system
Galvanometer scans the most widely (high precision and efficiency)
Lasers (stray light)
Beam expander (beam expander collimation)
Dynamic focus lens
Galvanometer
Material feeding device: directional, quantitative, tensioned conveying, fault alarm
Hot press laminating device
Exhaust and smoke exhaust device: green cleaning
computer control system
laser
cooler
Post-processing
scrap stripping
Hand peeling: paper stock
Heated peeling: High temperature melts the wax support structure
Chemical Peel: A chemical solution dissolves the support structure
Repair, polish, polish
Surface treatment: coating with paint, etc. to improve performance and lifespan
Advantages and Disadvantages
Advantages: higher efficiency, lower cost, cheap materials, no need to scan the entire section, no need to consider supports
Disadvantages: low tensile strength in the lamination direction, easy to absorb moisture and deform, waste materials need to be peeled off manually, which is time-consuming and labor-intensive, easy to deform during processing, and there are step patterns on the surface of the workpiece
Applications: Heavy structural parts models, physical appearance models, sand casting rapid mold masters, shoemaking industry, etc.
Fused Deposition Modeling (FDM)
Craftsmanship
Principle: The filamentary or granular hot-melt material is heated and melted, extruded through the nozzle, and formed layer by layer.
process
Pre-processing→Prototyping→Post-processing
Prototyping: 3D modeling → process parameter formulation
Material
molding material
Single molding material (widely used): ABS, PLA, PEEK, paraffin, nylon, TUP, PC, PPSF
Composite molding materials (not widely used): matrix materials (wax, plastic) reinforcement materials (metal powder, ceramic powder, etc.)
It appears as the temperature changes: glassy state → highly elastic state → viscous flow state (suitable for extrusion)
Support material: easily removed from the molded part without damaging the surface
For water-soluble supports, soapy water can be used
Performance requirements: Larger melting temperature-oxidation point temperature range
Thermophysical properties of polymer materials
Thermal properties: thermal conductivity coefficient
Rheological properties: Melt viscosity
The fused deposition process requires a reasonable matching of heating chamber temperature and wire feed speed.
Decreases with increasing temperature
Increases with increasing pressure
Decreases as the shear rate increases (the distance between molecules increases and the force decreases)
Systems and equipment
nozzle
most complex
Plunger nozzle
silk material
Screw nozzle
silk material
Granules
Movement mechanism
Wire feeding mechanism
Overflow nozzle structure
heating system
Advantages and Disadvantages
advantage
Low running costs
Wide range of molding materials
Environmental friendly
Post-processing is simple
Can be manufactured on desktop (easy to popularize)
shortcoming
Low molding accuracy
Molding speed is slow
Low strength in Z direction
Support materials are required, and large parts are prone to warping and deformation.
Forming error
Principle
Caused by molding system
Forming table error
Synchronous belt deformation error
Positioning error
STL file conversion error
stratification processing error
Craftsmanship
caused by material shrinkage
Caused by molding process parameter settings
Wire outlet width
Nozzle temperature
Interaction between filling speed and extrusion speed
Fill style
Caused by the nozzle start and stop response
post processing
Caused by removal of supports
Post-curing and surface treatment produce
Selective Laser Sintering Technology (SLS)
The United States invented it in 1986 and successfully developed the first machine in 1988
Craftsmanship
principle
The powder material is sintered under laser irradiation and layered layer by layer under computer control.
solid phase sintering
Suitable for ceramic and metal powders
chemical sintering
For example: aluminum powder is sintered in nitrogen, aluminum nitride can be used as a binder
Liquid phase sintering and partial melting
Melted part used as adhesive
completely melted
Metal parts have the highest density
Laser sintering mechanism
Viscous flow sintering mechanism ~ suitable for polymers
Surface tension of powder particles ~ as driving force for viscous flow sintering
The growth rate of sintering necks between powder particles is directly proportional to the surface tension of the material and inversely proportional to the particle radius and melt viscosity
Post-processing
High temperature sintering: reduce pores and enhance performance
Hot isostatic pressing: heating and pressing
Dip: immersion in liquid metal
Impregnation: liquid non-metallic impregnation
Impact of process parameters
Laser energy and scanning speed
Preheating temperature and powder layer thickness
Fill spacing affects strength
Layer thickness affects strength
Material
Various powders
Polymer materials
metal based powder
Binder➕Metal powder~needs degreasing, high-temperature sintering, and metal infiltration treatment
Low melting point metal powder➕High melting point metal powder
Coated sand material: thermosetting resin quartz sand
Material properties
particle size
particle size distribution
particle shape
Core device
laser
Galvanometer scanning system
Powder delivery system
Molding chamber
Gas protection system
Preheating system
advantage
Wide range of molding materials
High material utilization rate
Simple process, no support required
Wide range of applications
Selective Laser Melting Technology (SLM)
Craftsmanship
principle
Use high-energy laser beams to completely melt the metal powder and then quickly cool and solidify it to obtain high-density, high-precision, metallurgically bonded metal parts.
The principle of the SLS process is the same, but a fiber laser (high power) is used to completely melt the metal powder into shape, without the need for degreasing, secondary sintering, and infiltration treatment.
SLM technology
laser energy delivery
Low energy suitable for preheating
Excessive energy can cause damage to molded parts
light energy absorptivity
Suitable for titanium-based, iron-based, nickel-based alloys with high absorption rates
Melt pool stability
Suitable laser spot size
Too big: The size of the molten pool is large, more powder enters, and the instability increases
Too small: The energy is too high for gasification, and the ion flow impacts the molten pool.
Powder properties
Packing characteristics: powder bed porosity ~ negatively correlated with particle sphericity
particle size distribution
Fluidity: The higher the sphericity, the higher the fluidity and the higher the density.
Oxygen content: Too high will reduce the wettability of the solution and cause delamination and cracks.
process
Material preparation
Working chamber preparation
Model preparation
Parts processing
Parts post-processing
molding material
elemental powder
mixed powder
Pre-alloyed powder
Metal powder with high absorption rate of laser energy
equipment
Main mechanical structure
Laser (fiber laser)
Optical transmission system
control system
software system
Advantages and Disadvantages
advantage
Wide range of molding materials
Fine grains, uniform structure, and excellent mechanical properties
High density
High molding accuracy
shortcoming
Defects such as warping deformation, spheroidization, pores, and cracks are prone to occur
Formable parts are limited in size
Complex process parameters
Technology and equipment are mostly monopolized by foreign countries
high power laser
High-precision galvanometer system
Electron Beam Selective Melting Technology (EBSM)
Craftsmanship
principle
Using electron beam as heat source to melt metal powder, solidify and deposit it under vacuum conditions
parameter
electron beam current
accelerating voltage
Line scan speed
focus current
Scan line spacing
layer thickness
process
Molding materials and preparation
Materials include: stainless steel, titanium, titanium alloy powder, aluminum alloy, copper alloy, and other metal powders. SEBM titanium alloy is the most researched alloy.
Preparation method
Plasma rotating electrode atomization method and gas atomization method
Good sphericity, good fluidity, low oxygen content, easy to blow powder
Hydrodehydrogenation
Irregular shape, poor fluidity, stable, not easy to collapse, but high oxygen content
Usually the method of mixing two powders is used, and the comprehensive performance
equipment
electron gun system
electron gun
gate
Focusing coil
Deflection coil
Vacuum system
control system
software system
Advantages and Disadvantages
advantage
High energy density and power
No reflection, high energy utilization
Molded parts have high density and excellent performance
Fast and efficient
Little pollution
shortcoming
expensive
The electron beam focusing effect is poor, and the accuracy and quality are slightly worse.
There will be powder blowing problems
Solution
Use composite powder to reduce fluidity
Preheat the powder bed
Preheat the base plate
Optimize electron beam scanning method
The size of the molded parts is limited and the process parameters are complex.
Development trend
Materials
technical aspects
Molding equipment
Laser Engineered Net Shaping Technology (LENS)
Craftsmanship
principle
The shaped metal powder is sent to the molten pool formed by the laser through the powder feeding device and nozzle. The molten metal powder is deposited on the surface of the substrate and solidifies to form a deposition layer.
process
Model preparation
Material preparation
Feeding process
Parts processing
Parts post-processing
parameter
Powder morphology
pick-up rate
laser energy
molding material
Considerations
Packing characteristics
particle size distribution
particle shape
Liquidity
Oxygen content
Absorption rate of laser
Iron, nickel, titanium alloy and other powders
Mixing different particle sizes
equipment
laser system
CNC system
Powder feeding system
atmosphere control system
feedback control system
Advantages and Disadvantages
advantage
The material has superior organization and performance
Fast, save materials
Can directly manufacture parts with complex structures
Wide range of materials
Can process refractory metals
Repairable parts
shortcoming
There are metallurgical defects
volume shrinkage
powder explosion
Microcracks
residual stress
Low molding accuracy
Corner positions and cantilever structures are difficult to form
Powder raw materials are expensive
application
Gradient functional materials: advanced materials with excessive gradients in composition, structure, and properties
rapid mold making
Development direction
Craftsmanship
Materials
Real-time observation technology of laser coating process
Molding efficiency
Three-dimensional printing technology (3DP)
Process principle
Based on the principle of micro-droplet injection, the nozzle is used to selectively inject liquid binder, and the discrete powder is adhered and deposited layer by layer according to the path.
Curing method
Physical curing: solvent evaporates to form a bonding neck
Chemical curing: a chemical reaction occurs
Bonding method
hydration
Organic binder: metal powder, ceramic powder, resin (easy to remove)
Inorganic binder: add acidic powder silica sol (gel reaction, difficult to remove)
solvent method
metal salt method
molding material
base material
metal powder
ceramic powder
molding sand
polymer, gypsum
adhesive
Add materials
equipment
injection system
Continuous spray: array nozzle
spray on demand
Thermal foaming type
Micro voltage type
Powder supply system
motion control system
environmental control system
Hardware system
software system
Advantages and Disadvantages
advantage
lower cost
Wide range of molding materials
No need to add supports
High molding efficiency
Colorful printing is possible
shortcoming
Initial molded parts have low strength
Forming accuracy is low
Nozzles are easily clogged
application
Manufacturing of casting sand molds
Functional component production
Paramedicine
Pharmaceutical Engineering