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Submit a ProposalAdvances in Additive Manufacturing
 | Edited by Sandip Kunar, Jagadeesha T, S. Rama Sree, K.V.S.R. Murthy and M. Sreenivasa Reddy Series: Advances in Production Engineering Copyright: 2024 | Expected Pub Date:2024/04/30 ISBN: 9781394238286 | Hardcover | 512 pages |
One Line Description
This volume focuses on the fundamentals of additive manufacturing and its components, explains why and what we do, outlines what is crucial to the user, offers details on important applications such as in the aerospace, automotive, or medical areas, and the difficult certification process.
Audience
The book will be used by engineers and R&D researchers involved in advanced additive manufacturing technology, postgraduate students in various disciplines such as mechanical, manufacturing, biomedical, and industrial engineering, etc. It will also serve as a reference manual for manufacturing and materials engineers involved in additive manufacturing and product development.
The book will be used by engineers and R&D researchers involved in advanced additive manufacturing technology, postgraduate students in various disciplines such as mechanical, manufacturing, biomedical, and industrial engineering, etc. It will also serve as a reference manual for manufacturing and materials engineers involved in additive manufacturing and product development.
Description
This book explores the advancements in additive manufacturing which produces solid, free-form, nearly net-shaped objects. This refers to items that are easy to use, out-of-the-box, and not bound by the design constraints of modern manufacturing techniques. AM expands the definition of 3D printing to encompass a variety of procedures that begin with a three-dimensional computer model, incorporate an AM production procedure, and result in a useful product. The AM process can be confusing due to the rapid rise of competing techniques for fabricating 3D parts. This volume provides a thorough review of the basic components and procedures involved in additive manufacturing. It outlines a road map for where to begin, what to study, how everything goes together, and how AM might enable ideas outside traditional processing to realize those ideas in AM. Furthermore, this book investigates the benefits of AM including affordable access to 3D solid modeling software. With this software, learning is achieved without having to invest in costly industrial equipment.
AM encompasses a variety of techniques, including those that use high-intensity beams to fuse powder or wire, and hybrid techniques that combine additive and subtractive manufacturing techniques. AM-related processes have developed at breakneck speed, giving rise to a deluge of acronyms and terminology, not to mention the emergence, acquisition, and demise of new businesses. By combining ideas and aspirations, better methods will be revealed that result in useful products that will serve and contribute to a lasting future.
Although expensive commercial additive manufacturing equipment can cost hundreds of thousands to millions of dollars, a lack of access to equipment does not preclude the study of the technology. 3D printing services will undoubtedly become more reasonable for small- and medium-sized organizations as their prices decline. Hybrid 3D plastic printing technologies and low-cost hobbyist 3D weld deposition systems are already in development which will make the best 3D printers accessible and affordable. This book will assist the reader in determining what is required to begin, which software, supplies, and procedures best suit, and where to obtain additional information.
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This book explores the advancements in additive manufacturing which produces solid, free-form, nearly net-shaped objects. This refers to items that are easy to use, out-of-the-box, and not bound by the design constraints of modern manufacturing techniques. AM expands the definition of 3D printing to encompass a variety of procedures that begin with a three-dimensional computer model, incorporate an AM production procedure, and result in a useful product. The AM process can be confusing due to the rapid rise of competing techniques for fabricating 3D parts. This volume provides a thorough review of the basic components and procedures involved in additive manufacturing. It outlines a road map for where to begin, what to study, how everything goes together, and how AM might enable ideas outside traditional processing to realize those ideas in AM. Furthermore, this book investigates the benefits of AM including affordable access to 3D solid modeling software. With this software, learning is achieved without having to invest in costly industrial equipment.
AM encompasses a variety of techniques, including those that use high-intensity beams to fuse powder or wire, and hybrid techniques that combine additive and subtractive manufacturing techniques. AM-related processes have developed at breakneck speed, giving rise to a deluge of acronyms and terminology, not to mention the emergence, acquisition, and demise of new businesses. By combining ideas and aspirations, better methods will be revealed that result in useful products that will serve and contribute to a lasting future.
Although expensive commercial additive manufacturing equipment can cost hundreds of thousands to millions of dollars, a lack of access to equipment does not preclude the study of the technology. 3D printing services will undoubtedly become more reasonable for small- and medium-sized organizations as their prices decline. Hybrid 3D plastic printing technologies and low-cost hobbyist 3D weld deposition systems are already in development which will make the best 3D printers accessible and affordable. This book will assist the reader in determining what is required to begin, which software, supplies, and procedures best suit, and where to obtain additional information.
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Author / Editor Details
Sandip Kunar, PhD, is an assistant professor in the Department of Mechanical Engineering, Aditya Engineering College, A.P., India. He has published more than 50 research papers in various reputed international journals, national and international conference proceedings, 16 book chapters, and 9 books as well as two patents. His research interests include non-conventional machining processes, micromachining processes, advanced manufacturing technology, and industrial engineering.
Sandip Kunar, PhD, is an assistant professor in the Department of Mechanical Engineering, Aditya Engineering College, A.P., India. He has published more than 50 research papers in various reputed international journals, national and international conference proceedings, 16 book chapters, and 9 books as well as two patents. His research interests include non-conventional machining processes, micromachining processes, advanced manufacturing technology, and industrial engineering.
Jagadeesha T, PhD, is an associate professor in the Department of Mechanical Engineering, National Institute of Technology Calicut, India. He has 25 years of industry and academic experience and has authored mechanical engineering workbooks and textbooks and published more than 75 papers in international and national journals/conferences. As well as four patents. His research interests are advanced machining, additive manufacturing, fluid power control, advanced materials, vibration and noise control, and FEM.
S. Rama Sree, PhD, is a professor in the Computer Science and Engineering Department, Aditya Engineering College, India. She has published more than 50 papers in international/national journals and conferences, four patents, and co-authored on data structures. Her research interests include software, soft computing, applications of machine learning techniques, medical diagnosis and cloud computing.
K.V.S.R. Murthy, PhD, is a professor in the Electrical and Electronics Engineering Department, Aditya Engineering College, India. He is an expert in power system operation and control, and the application of artificial intelligence techniques in power distribution systems. He has published 35 research papers in various journals/conferences.
M. Sreenivasa Reddy, PhD, is the Director of Aditya Group of Educational Institutions and Principal of Aditya Engineering College, India. He has more than 25 years of industry and academic experience and is an expert in additive manufacturing technology. He has 11 patents granted and published many journal articles and book chapters.
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Table of Contents
Preface
Acknowledgment
1. Fundamentals and Applications of Additive Manufacturing
Sandip Kunar, Jagadeesha T., Gurudas Mandal, Akhilesh Kumar Singh and S. Rama Sree
1.1 Basics and Definitions
1.1.1 Additive Manufacturing
1.1.2 Theory of Layer-Based Technology
1.1.3 Additive Manufacturing (AM)
1.2 Application Levels
1.2.1 Direct Processes
1.2.1.1 Rapid Prototyping
1.2.1.2 Rapid Manufacturing
1.2.1.3 Rapid Tooling
1.3 Application Levels – Indirect Processes
1.3.1 Indirect Prototyping
1.3.2 Indirect Tooling
1.3.3 Indirect Manufacturing
1.4 Machines for Additive Manufacturing
1.5 Conclusions
References
2. Characteristics of Additive Manufacturing Process
Sandip Kunar, Jagadeesha T., Gurudas Mandal, Akhilesh Kumar Singh, Rajesh Kumar, Aezeden Mohamed and Param Singh
2.1 Basic Principles
2.2 Generation of Layer Information
2.2.1 Description of the Geometry by a 3D Data Record
2.2.1.1 Data Flow and Interfaces
2.2.1.2 Modeling by 3D CAD
2.2.1.3 Creating 3D Models from Measurements
2.2.2 Creation of Geometrical Layer Information on Single Layers
2.2.2.1 STL Format
2.2.2.2 CLI/SLC Format
2.2.2.3 PLY and VRML Formats
2.2.2.4 AMF Format
2.3 Physical Principles for Layer Formation
2.3.1 Solidification of Liquid Materials
2.3.1.1 Photopolymerization–Stereolithography (SL)
2.3.1.2 Fundamentals of Polymerization
2.3.2 Creation from the Solid Phase
2.3.2.1 Melting and Solidification of Powders and Granules
2.3.2.2 Cutting from Foils: Layer Laminate Manufacturing (LLM)
2.3.2.3 Extrusion and Ballistic Methods
2.3.2.4 Conglutination of Granules and Binders: 3D Printing
2.3.3 Solidification from the Gas Phase
2.3.3.1 Aerosol Printing Method
2.3.3.2 Laser Chemical Vapor Deposition (LCVD)
2.3.4 Other Processes
2.4 Summary Evaluation of Rapid Prototyping Methods
2.4.1 Materials
2.4.2 Model Properties
2.4.3 Accuracy
2.4.4 Surface Quality
2.4.5 Development Potential
2.4.6 3D Model Generation
2.5 Conclusion
References
3. Directed Energy Deposition (DED) Process
M. Sivakumar, N.S. Balaji, G. Rajesh Kannan and R. Karthikeyan
3.1 Introduction
3.2 Direct Energy Deposition (DED)
3.2.1 Principles and Mechanisms
3.2.2 Overview of Powder DED and Wire DED Process
3.2.2.1 Wire Feeding Type DED Processes
3.2.2.2 Applications of WAAM
3.2.3 Wire and Laser Additive Manufacturing (WLAM) Process
3.2.3.1 Powder Delivery Nozzles
3.2.3.2 Applications of WLAM
3.2.4 Wire and Electron Beam Additive Manufacturing (WEBAM) Process
3.2.4.1 Applications of WEAM
3.3 Materials Used in the DED Process
3.3.1 Process Parameters
3.4 Hybrid DED Process
3.5 In Situ Monitoring in DED
3.6 Case Studies
3.7 Limitations and Challenges
3.8 Applications of DED Process
Summary
References
4. Current Progress and Future Perspectives of Biomaterials in 3D Bioprinting
Prerona Saha, Ankita Nandi, Jaideep Adhikari, Abhishek Ghosh, Asiful H. Seikh and Manojit Ghosh
4.1 Introduction
4.1.1 Biomaterial Combinations for 3D Bioprinting
4.2 Biomaterials Used in Designing a Bioink
4.2.1 Protein-Based Bioink
4.2.2 Polysaccharide-Based Bioink
4.2.3 Synthetic Bioink
4.2.4 Multi-Material Bioinks
4.2.5 Stimuli-Responsive Materials
4.2.6 Dynamic Bioinks
4.3 Growth Factors Used in Bioink
4.4 Bioimaging of Bioink
4.5 Extracellular Vesicle Loaded Bioink
4.6 Requirements for Ideal 3D Bioprinting Materials
4.7 3D Bioprinting Technologies
4.7.1 Droplet-Based Bioprinting (DBB)
4.7.1.1 Advantages and Disadvantages
4.7.1.2 Types of Droplet-Based Bioprinting
4.7.2 Extrusion-Based Bioprinting (EBB)
4.7.2.1 Advantages and Disadvantages
4.7.2.2 Hydrogels Used and Their Significance
4.7.3 Laser-Assisted Bioprinting (LAB) or Light-Assisted Bioprinting
4.7.3.1 LAB Setup
4.7.3.2 Advantages and Disadvantages
4.7.4 Stereolithography
4.7.4.1 The Setup for Stereolithography
4.7.4.2 Applications of Stereolithography
4.8 Challenges Faced by 3D Bioprinting Techniques
4.9 Conclusion
References
5. Powder Bed Fusion Process – State of Art
G. Rajesh Kannan, M. Sivakumar, B. Jagadeesh and N. S. Balaji
5.1 Introduction
5.2 Powder Bed Fusion (PBF)
5.2.1 Working Principle of PBF Process
5.2.2 Classification of Powder Bed Fusion Process
5.2.3 Process Parameters of Powder Bed Fusion Process
5.2.4 Effects of Heat in Powder Bed Fusion Process
5.3 Laser Powder Bed Fusion (L-PBF)
5.3.1 Why is the Term ‘Selective Laser Sintering’ Misleading?
5.3.2 Process Flow of L-PBF
5.3.3 Process Parameters for Laser Powder Bed Fusion
5.3.3.1 Laser Specifications
5.3.3.2 Component Parameters
5.3.3.3 Environment-Related Variables
5.3.4 The Impact of L-PBF Process Parameters on the Occurrence of Build Defects
5.3.5 Data Processing for Identification of Spatter-Related Issues
5.4 The Influence of L-PBF Processing Parameters on the Microstructure
5.5 Merits and Demerits of Powder Bed Fusion Process
5.5.1 Merits of Powder Bed Fusion
5.5.2 Demerits of Powder Bed Fusion
5.6 Applications of Powder Bed Fusion Process
5.7 Summary
References
6. Cobalt-Chromium Alloy Additive Manufacturing Technologies for Biomedical Applications
Pravin Pawar, Amaresh Kumar and Raj Ballav
6.1 Introduction
6.2 Selective Laser Melting (SLM) Additive Manufacturing
6.3 Laser Powder-Bed-Fusion (LPBF) Additive Manufacturing
6.4 Direct-Metal Laser-Sintering (DMLS) Additive Manufacturing
6.5 Selective Laser Sintering (SLS) Additive Manufacturing
6.6 Laser Melting (LM) Additive Manufacturing
6.7 Electron Beam Melting (EBM) Additive Manufacturing
6.8 Micro-Plasma Based Additive Manufacturing (MPBAM)
6.9 Direct Metal Fabrication (DMF) Additive Manufacturing
6.10 Wire and Arc Additive Manufacturing (WAAM)
6.11 Summary of Additive Manufacturing Technologies of Cobalt-Chromium Alloy Material for Bio-Medical Applications
6.12 Conclusion
References
7. Cold Spray Additive Manufacturing: Principles, Applications, and Recent Advancements
Jagadeesha T. and Sandip Kunar
7.1 Introduction
7.2 Literature Review
7.3 Phenomena and Factors Behind CSAM
7.4 Numerical Simulation of CSAM
Conclusion
Future Scope
References
8. Integrating Metal Forming and Additive Manufacturing for Enhanced Product Quality and Efficiency
Jagadeesha T. and Sandip Kunar
8.1 Introduction
8.2 Need of Additives in Metal Forming Process
8.3 Erichsen Test
8.4 Types of Additives
8.4.1 Slip Additives
8.4.2 Polymer Additives
8.4.3 Fluorinated Additives
8.4.4 Nanoparticle Additives
8.4.5 Hybrid Wire Arc Additive
8.4.6 Metal Additives
8.5 Effects of Additives in Various Processes
8.5.1 Impact of Slip Additive
8.5.2 Impact of Polymer Additives
8.5.3 Impact of Nano Additives
8.5.4 Impact of Metal Additives
8.5.5 Impact of Hybrid Wire – Arc Additive
8.6 Traditional Sheet Metal Forming and Additive Manufacturing
8.7 Technologies Used in Metal Forming That Involves Additives
8.8 General Impacts of Additives in Additive Manufacturing
8.8.1 Manufacturing Impacts
8.8.2 Environmental Impacts
8.8.3 Consumption of Energy
8.8.4 Environmental Risks
8.8.5 Affinity Towards Atmosphere Constituents
8.8.6 Thermal Conductivity and High Reflectivity
8.8.7 Residual Stress
8.9 Factors Affecting Additive Manufacturing
8.9.1 Surface Finish, Size, and Scaling of Geometry
8.9.2 Atmosphere of Build Chamber
8.9.3 Quality of Feedstock
8.9.4 Interactions Between Beam and Powder
8.9.5 Porosity
8.9.6 Swelling, Delamination and Cracking
8.9.7 Residual Stress
8.10 Conclusion
References
9. Impacts of Additives on Failure Issues Linked with Additively Manufactured Products
Jagadeesha T. and Sandip Kunar
9.1 Introduction
9.2 Additive Manufacturing
9.3 Technological Aspects
9.3.1 Impact of Additives in Manufacturing Processes
9.4 Challenges in Additive Manufacturing
9.5 Limitations and Future Scope
9.6 Conclusion
References
10. Nano-Additives for Advanced Additive Manufacturing: Enhancing Quality,
Sustainability and Performance
Jagadeesha T. and Sandip Kunar
10.1 Introduction
10.2 Application of Nano-Additives
10.3 Literature Survey
10.4 Methodology
10.4.1 Plasma Electrolytic Oxidation (PEO) for Mg and Its Alloys
10.4.2 Role of Nano-Additives in Piezoelectric Properties Enhancement of Potassium Sodium Niobate/Polyvinylidene Fluoride
10.4.3 Role of Nano-Additives in the Shape Retention Properties of 3D Printed Multibinder Geopolymer
10.4.4 Role of Nano-Additives in the Sintered TiC Ceramics
10.4.5 Role of Nano-Additives in UHPC Mix
10.4.6 Role of Nano-Additives in β-C2S Stabilization Purpose
10.4.7 Role of Nano-Additives in Zirconium Diboride UHTCs
10.5 LAM of the Titanium Carbide Nanoparticles Strengthened by Nickel Based Nano-Size Composites
10.6 Role of Nano-Additives to Enhance the Fuel Properties of Tyre Oil for Green Environment
10.7 Conclusion
References
11. Processing of Biomaterials by Additive Manufacturing
R. Prayer Riju, S. Arulvel, D. Dsilva Winfred Rufuss, Jayakrishna Kandasamy and P. Jeyapandiarajan
11.1 Introduction
11.2 Diverse Additive Manufacturing Techniques for Processing Biomaterials
11.2.1 Stereolithography (SLA)
11.2.1.1 SLA – Post-Processing
11.2.2 Fused Deposition Modelling (FDM)
11.2.2.1 Post-Processing of FDM Printed Biomaterial
11.2.3 Inkjet Printing
11.2.3.1 Post-Processing of Inkjet-Printed Biomaterial
11.2.4 Selective Laser Sintering (SLS)
11.2.4.1 Post-Processing of SLS Printed Biomaterial
11.2.5 Selective Laser Melting
11.2.5.1 Post-Processing of SLM Printed Biomaterial
11.2.6 Laser-Assisted Bio-Printing (LAB)
11.2.7 Direct Ink Writing (DIW)
11.2.7.1 Post-Processing of DIW Printed Biomaterial
11.3 Conclusion
References
12. Safety and Environmental Protection in Additive Manufacturing
N.S. Balaji, M. Sivakumar, G. Rajesh Kannan and R. Karthikeyan
12.1 Introduction
12.1.1 Environmental Sustainability Through Additive Manufacturing
12.1.2 Safety in Additive Manufacturing
12.2 Environmental Impacts of Additive Manufacturing
12.2.1 Embracing Sustainable Manufacturing
12.2.2 The Importance of Sustainability
12.2.3 Eco-Conscious Manufacturing
12.2.4 Waste Reduction and Resource Efficiency
12.2.5 Lean Manufacturing in a Competitive Market
12.3 Additive Manufacturing: A Sustainable Approach to Reducing Environmental Degradation
12.3.1 Advancements in Additive Manufacturing for Environmental Enhancement
12.3.1.1 Efficiency and Precision in Manufacturing
12.3.1.2 Customization and Innovation
12.3.1.3 Diverse Applications and Sustainability in Architecture
12.3.1.4 Environmental Benefits of AM
12.3.1.5 Positive Impact on Pollution Control
12.4 Developing a Sustainable Additive Manufacturing Ecosystem: Basic Building Blocks
12.4.1 Safety in Additive Manufacturing
12.4.2 Economic Features of AM
12.4.3 Environmental Sustainability in AM
12.4.4 Societal Impacts and Benefits
12.5 Enriching Sustainability Through Additive Manufacturing Processes: A Sequential Overview
12.6 AM Security and Safety: A Comprehensive Approach
12.6.1 AM Security and Safety: A Comprehensive Analysis
12.7 Summary
References
13. Advanced Developments in Additive Manufacturing of Silicone Rubber
Elastomers
Mohammad Bagher Jafari, Hossein Doostmohammadi, Mostafa Baghani and Majid Baniassadi
13.1 Introduction
13.2 Chemical Structure and Properties of Silicone Rubbers
13.2.1 Chemical Structure
13.2.2 Curing
13.3 Additive Manufacturing Techniques for Fabrication of Silicone Rubber Structures
13.4 3D Printable Silicone-Based Materials
13.4.1 Liquid Silicone Elastomer
13.4.2 Room Temperature Vulcanizing
13.4.3 High Consistency Silicone Rubber
13.5 Progress and Applications Proposed for 3D Printed Silicone Rubbers
13.5.1 Soft Robotics
13.5.2 Prosthetic Devices and Stents
13.5.3 Drug Delivery
13.5.4 Soft Electronics and Sensors
13.6 Challenges and Future Research Direction
13.7 Conclusion
References
14. Laser-Assisted Additive Manufacturing Techniques for Advanced Composites
Nitai Chandra Adak, Fahim Sharia and Wonoh Lee
14.1 Introduction
14.2 Classification of Laser-Based Additive Micromanufacturing Techniques
14.2.1 Selective Laser Sintering (SLS)
14.2.2 Direct Metal Laser Sintering (DMLS)
14.2.3 Selective Laser Melting (SLM)
14.2.4 3D Laser Printing Systems
14.2.4.1 Stereolithography Apparatus (SLA)
14.2.4.2 Digital Light Projection
14.2.4.3 Two-Photon Polymerization
14.2.4.4 Solid Ground Curing
14.3 Challenges in Laser-Based Additive Manufacturing of Composites
14.4 Conclusions and Future Research Opportunities
References
15. Stereolithography-Based Polymer Additive Manufacturing Process for Microfluidics Devices: A Review
Ajit Biswas, Amit Kumar Singh and Debasree Das
15.1 Introduction
15.1.1 Microfluidics: An Overview
15.1.2 Significance of Additive Manufacturing in Microfluidics
15.1.3 Novel Insights and Research Importance
15.1.4 Objective of the Review
15.2 Polymer Additive Manufacturing Processes
15.2.1 Material Extrusion
15.2.2 Binder Jetting
15.2.3 Polymer Powder Bed Fusion (P-PBF)
15.2.4 Vat Photopolymerization
15.3 Stereolithography (SLA) for Microfluidics
15.3.1 Working Principle and Process Flow
15.3.2 Suitable Polymers for SLA-Based Microfluidic Devices
15.3.2.1 Epoxy Resins
15.3.2.2 Polyurethane Resins
15.3.2.3 Acrylic Resins
15.3.2.4 Photopolymer Resins
15.3.2.5 Silicone Resins
15.3.2.6 Polyetherimide Resins
15.3.2.7 Polycarbonate Resins
15.3.3 Advantages and Limitations of SLA for Microfluidics Devices
15.3.4 Examples of SLA-Based Microfluidic Applications
15.4 Applications of Polymer Additive Manufacturing in Microfluidics
15.4.1 Biomedical Applications of Polymer Additively Manufactured Microfluidics Devices
15.4.1.1 Lab-on-a-Chip Devices for Diagnostics and Disease Monitoring
15.4.1.2 Lab-on-a-Chip Devices for Point-of-Care Diagnostics
15.4.1.3 Organ-on-a-Chip Platforms for Drug Screening and Personalized Medicine
15.4.1.4 Microfluidic Devices for Cell Culture and Tissue Engineering
15.5 Challenges and Future Prospects of Polymer Additive Manufacturing Processes in Microfluidics
15.6 Conclusion
References
16. Biomaterials and Bioinks: A Synergistic Approach to Bioprinting
M. Abdur Rahman, G. Rajesh and N. Sri Rangarajalu
16.1 Introduction
16.1.1 Bioprinting
16.1.1.1 Drug Delivery Systems
16.2 Bioprinting
16.2.1 The Process of 3D Bioprinting Involves Several Key Steps
16.2.1.1 Bioink Formulation
16.2.1.2 Key Aspects that Highlight the Importance of Bioinks
16.3 Extrusion-Based Bioprinting
16.3.1 Benefits of Extrusion-Based Bioprinting
16.3.1.1 The Main Elements of Extrusion-Based Bioprinting
16.3.1.2 Applications of Extrusion-Based Bioprinting
16.4 Inkjet-Based Bioprinting
16.4.1 Inkjet-Based Bioprinting Has Several Advantages
16.5 Significant Aspects of Bioprinting
16.5.1 Bioprinting in Regenerative Medicine
16.5.1.1 Bioprinting for Implants and Medical Devices
16.5.1.2 Important Moral and Legal Issues with Bioprinting
16.5.1.3 New Developments in 3D Bioprinting of Complicated Organs and Tissues
Conclusion
References
17. Significance of Additive Manufacturing in Aerospace and Automotive Industries
M. Abdur Rahman, Ravi Kumar S. and A.S. Selvakumar
17.1 Introduction to Additive Manufacturing (AM) in the Aerospace and Automotive Industry
17.2 AM Processes in the Aerospace Industry
17.3 AM Processes in the Automotive Industry
17.4 AM Applications of Automotive and Aerospace Industries
17.4.1 AM’s Applications in the Automotive Industry
17.4.2 Aerospace Applications of AM
17.5 Material Selection in AM
17.6 DfAM in Aerospace Applications and Automotive Applications
17.7 Supply Chain and Manufacturing Integration in the Aerospace Industry
17.8 Supply Chain and Manufacturing Integration in the Automotive Industry
17.9 Maintenance, Repair, and Overhaul (MRO) in Aerospace AM
17.10 Maintenance, Repair, and Overhaul (MRO) in Automotive AM
17.11 Circular Economy in the Aerospace Industry
17.12 Circular Economy in the Automotive Industry
17.13 Conclusion
17.14 Future Scope
References
18. Sustainability and Efficiency: The Green Potential of Additive Manufacturing
M. Abdur Rahman, Serajul Haque, N. Sri Rangarajalu and D. R. Rajendran
18.1 Introduction to Additive Manufacturing (AM) and Its Role in Sustainability
18.1.1 Key Principles of Additive Manufacturing
18.1.1.1 Historical Development and Growth of AM in Various Industries
18.2 The Relevance of AM in the Context of Sustainability and Efficiency
18.2.1 Environmental Impact Assessment
18.2.2 Consumption of Resources
18.2.2.1 Traditional Manufacturing’s Energy Consumption
18.3 Life Cycle Assessment (LCA) of AM Processes and Products
18.4 Identification of Key Environmental Hotspots in AM Technology
18.5 Sustainable Materials and Additive Manufacturing
18.5.1 Exploration of Sustainable Materials for AM
18.6 Biodegradable and Recycled Materials in AM
18.7 The Potential for Renewable Energy Integration in AM Processes
18.8 Waste Reduction and Circular Economy in Additive Manufacturing
18.8.1 Strategies for Minimizing Waste in AM
18.8.2 Eco-Friendly Alternatives in Additive Manufacturing
18.9 Research and Development Areas to Enhance AM’s Green Potential
18.9.1 Potential Challenges and Opportunities in the Future of Green AM
18.10 Conclusion
18.10.1 Future Prospects: Green Potential of AM
References
19. Role of Additive Manufacturing in IoT Medical Devices
K. Vijetha, Uzwalkiran Rokkala and Lingaraju Dumpala
19.1 Introduction
19.2 Additive Manufacturing
19.2.1 Additive Manufacturing for Medical Devices
19.2.2 Benefits of 3D Printing
19.2.3 Additive Manufacturing (AM) with Internet of Things
19.3 Future Scope for IoT
19.4 Conclusions
References
20. Additive Manufacturing of Superhydrophobic Architectures
Hossein Doostmohammadi, Majid Baniassadi and Mostafa Baghani
20.1 Introduction
20.2 Principles of Superhydrophobicity of Structures
20.2.1 Wettability, Surface Tension, and Contact Angle
20.2.2 Wenzel and Cassie-Baxter Regimes
20.3 Additive Manufacturing Techniques and Methods for Creation of Superhydrophobic Surfaces
20.3.1 Two Photon Polymerization 3D Printing
20.3.2 Stereolithography
20.3.3 Selective Laser Sintering
20.3.4 Digital Light Processing
20.3.5 Fused Deposition Modeling
20.3.6 Other 3D Printing Techniques
20.4 Advantages and Disadvantages of 3D Printing Techniques
20.5 Conclusion, Challenges, and Future Outlook
References
21. Fiber-Reinforced Composite and Topology Optimization in Additive Manufacturing
Tien-Dat Hoang and Van Du Nguyen
21.1 Introduction
21.2 Printed Model Without Fiber Reinforcement
21.2.1 3D Model and Material Properties
21.2.2 Printing Lattice Settings
21.2.3 Simulation and Experiment Results
21.2.3.1 Simulation Setting
21.2.3.2 Experiment Settings
21.2.3.3 Comparison Between Simulation and Experiment Results
21.3 Printed Model with Continuous Fiber Reinforcement
21.3.1 3D Printing Model
21.3.2 Tensile Simulation for Predict Stiffness and Deformation
21.4 Printing Model Integrating Topology Optimization and Continuous Fiber Reinforcement
21.4.1 Level Set-Based Multi-Material Topology Optimization
21.4.2 Topological Design Procedure
21.5 Conclusion
Acknowledgement
References
22. Comparative Analysis of Mechanical Characteristics in Additive Manufacturing on Polylactic Acid and Acrylonitrile Butadiene Styrene Materials
Kaustubh Pravin Joshi and Anil Dube
22.1 Introduction
22.2 Literature Review
22.3 Experimental Setup
22.3.1 Process
22.3.2 Testing
22.4 Results and Discussion
22.5 Conclusion
References
23. A Comprehensive Review on Polymers and Metal Additive Manufacturing
Praveena B. A., Santhosh N. and Anand G.
23.1 Introduction
23.2 Additive Manufacturing Processes and Methods
23.2.1 Fundamental Principles
23.2.2 Key Processes and Techniques in Polymer Additive Manufacturing
23.2.3 Key Processes and Techniques in Metal Additive Manufacturing
23.3 Materials for Additive Manufacturing
23.4 Additive Manufacturing Applications
23.4.1 Applications in Polymers Additive Manufacturing
23.4.2 Applications in Metal Additive Manufacturing
23.5 Challenges and Limitations
23.6 Future Directions and Opportunities
23.7 Conclusion
References
24. Sub-Zero Additive Manufacturing: A Green Solution to Pattern Making in the Investment Casting Industry
Pushkar Kamble, K. P. Karunakaran and Yicha Zhang
24.1 Introduction
24.2 Process of Using Ice Patterns by Sub-Zero Additive Manufacturing
24.2.1 Case Study 1
24.2.2 Case Study 2
24.3 Economic Comparison
24.4 Conclusions
24.5 Future Scope
References
25. Effect of Orientation on the Tensile Strength of 3D Printed Rectangular Solid Bars
Neel Kamal Gupta and Pawan Kumar Rakesh
25.1 Introduction
25.2 Modelling and Simulation
25.2.1 CAD Modelling
25.2.2 Material Properties
25.2.3 Modelling of Rectangular Solid Bar
25.3 Manufacturing of Rectangular Solid Bar by PolyJet Printing Technology
25.3.1 Manufacturing of Rectangular Solid Bar by FDM Technology
25.3.2 Tensile Test of Rectangular Solid Bar
25.4 Design of Experiment
25.5 Selection of Process Parameters
25.6 Selection of Orthogonal Array
25.7 Conclusion and Future Scope
References
26. Advanced Techniques in Wire Arc Additive Manufacturing: Monitoring, Control, and Automation
M. Sivakumar, R. Karthikeyan, N.S. Balaji and G. Rajesh Kannan
26.1 Introduction
26.2 Wire Arc Additive Manufacturing
26.2.1 Introduction to Wire Arc Additive Manufacturing
26.2.2 Principle of Mechanism
26.2.3 Advantages and Challenges of WAAM
26.3 Defects in the WAAM Process
26.4 Sensing Technology in Additive Manufacturing and Challenges in WAAM
26.4.1 Difficulties in Sensing Methods for Wire Arc Additive Manufacturing
26.4.2 Vision Sensing
26.4.3 Spectral Sensing
26.4.3.1 Spectral Sensing in WAAM
26.4.4 Acoustic Sensing
26.4.5 Thermal Sensing
26.5 Quality Control Strategies for WAAM
26.6 Automation in Wire Arc Additive Manufacturing
26.6.1 Automation Methods in WAAM
26.7 Case Study: Implementing a Closed-Loop Multiple Sensors System for Quality Control in the WAAM Process
26.7.1 The Challenge
26.7.2 Closed-Loop Control System
26.7.2.1 Three-Step Closed-Loop System
26.7.2.2 Quality Control Strategy
26.7.3 Solution of Case Study
26.7.4 Implementation and Results
Summary
References
27. Vat Photopolymerization
J. Suresh Kumar, Akshaya Senthilkumar, S. Naveen Rajkumar and K. Kalaichelvan
27.1 Introduction
27.2 Vat Polymerization Process
27.2.1 Pre-Building Process
27.2.2 Post-Building Process
27.2.3 Materials
27.3 Vat Polymerization Techniques
27.3.1 Stereolithography (SLA)
27.3.2 Digital Light Processing (DLP)
27.3.3 Continuous Digital Light Processing (CDLP)/Continuous Liquid Interface Production (CLIP)
27.3.4 Two-Photon Polymerization (2PP)
27.3.5 Liquid Crystal Display–Stereolithography (LCD–SLA)
27.4 Photoinitiator Materials
27.4.1 Radical Mechanism of Chain Growth
27.4.2 Cationic Mechanism of Chain Growth
27.5 Applications
27.5.1 Medical Applications
27.5.2 Mechanical Applications
27.5.3 Other Applications
References
Index
Back to Top
Preface
Acknowledgment
1. Fundamentals and Applications of Additive Manufacturing
Sandip Kunar, Jagadeesha T., Gurudas Mandal, Akhilesh Kumar Singh and S. Rama Sree
1.1 Basics and Definitions
1.1.1 Additive Manufacturing
1.1.2 Theory of Layer-Based Technology
1.1.3 Additive Manufacturing (AM)
1.2 Application Levels
1.2.1 Direct Processes
1.2.1.1 Rapid Prototyping
1.2.1.2 Rapid Manufacturing
1.2.1.3 Rapid Tooling
1.3 Application Levels – Indirect Processes
1.3.1 Indirect Prototyping
1.3.2 Indirect Tooling
1.3.3 Indirect Manufacturing
1.4 Machines for Additive Manufacturing
1.5 Conclusions
References
2. Characteristics of Additive Manufacturing Process
Sandip Kunar, Jagadeesha T., Gurudas Mandal, Akhilesh Kumar Singh, Rajesh Kumar, Aezeden Mohamed and Param Singh
2.1 Basic Principles
2.2 Generation of Layer Information
2.2.1 Description of the Geometry by a 3D Data Record
2.2.1.1 Data Flow and Interfaces
2.2.1.2 Modeling by 3D CAD
2.2.1.3 Creating 3D Models from Measurements
2.2.2 Creation of Geometrical Layer Information on Single Layers
2.2.2.1 STL Format
2.2.2.2 CLI/SLC Format
2.2.2.3 PLY and VRML Formats
2.2.2.4 AMF Format
2.3 Physical Principles for Layer Formation
2.3.1 Solidification of Liquid Materials
2.3.1.1 Photopolymerization–Stereolithography (SL)
2.3.1.2 Fundamentals of Polymerization
2.3.2 Creation from the Solid Phase
2.3.2.1 Melting and Solidification of Powders and Granules
2.3.2.2 Cutting from Foils: Layer Laminate Manufacturing (LLM)
2.3.2.3 Extrusion and Ballistic Methods
2.3.2.4 Conglutination of Granules and Binders: 3D Printing
2.3.3 Solidification from the Gas Phase
2.3.3.1 Aerosol Printing Method
2.3.3.2 Laser Chemical Vapor Deposition (LCVD)
2.3.4 Other Processes
2.4 Summary Evaluation of Rapid Prototyping Methods
2.4.1 Materials
2.4.2 Model Properties
2.4.3 Accuracy
2.4.4 Surface Quality
2.4.5 Development Potential
2.4.6 3D Model Generation
2.5 Conclusion
References
3. Directed Energy Deposition (DED) Process
M. Sivakumar, N.S. Balaji, G. Rajesh Kannan and R. Karthikeyan
3.1 Introduction
3.2 Direct Energy Deposition (DED)
3.2.1 Principles and Mechanisms
3.2.2 Overview of Powder DED and Wire DED Process
3.2.2.1 Wire Feeding Type DED Processes
3.2.2.2 Applications of WAAM
3.2.3 Wire and Laser Additive Manufacturing (WLAM) Process
3.2.3.1 Powder Delivery Nozzles
3.2.3.2 Applications of WLAM
3.2.4 Wire and Electron Beam Additive Manufacturing (WEBAM) Process
3.2.4.1 Applications of WEAM
3.3 Materials Used in the DED Process
3.3.1 Process Parameters
3.4 Hybrid DED Process
3.5 In Situ Monitoring in DED
3.6 Case Studies
3.7 Limitations and Challenges
3.8 Applications of DED Process
Summary
References
4. Current Progress and Future Perspectives of Biomaterials in 3D Bioprinting
Prerona Saha, Ankita Nandi, Jaideep Adhikari, Abhishek Ghosh, Asiful H. Seikh and Manojit Ghosh
4.1 Introduction
4.1.1 Biomaterial Combinations for 3D Bioprinting
4.2 Biomaterials Used in Designing a Bioink
4.2.1 Protein-Based Bioink
4.2.2 Polysaccharide-Based Bioink
4.2.3 Synthetic Bioink
4.2.4 Multi-Material Bioinks
4.2.5 Stimuli-Responsive Materials
4.2.6 Dynamic Bioinks
4.3 Growth Factors Used in Bioink
4.4 Bioimaging of Bioink
4.5 Extracellular Vesicle Loaded Bioink
4.6 Requirements for Ideal 3D Bioprinting Materials
4.7 3D Bioprinting Technologies
4.7.1 Droplet-Based Bioprinting (DBB)
4.7.1.1 Advantages and Disadvantages
4.7.1.2 Types of Droplet-Based Bioprinting
4.7.2 Extrusion-Based Bioprinting (EBB)
4.7.2.1 Advantages and Disadvantages
4.7.2.2 Hydrogels Used and Their Significance
4.7.3 Laser-Assisted Bioprinting (LAB) or Light-Assisted Bioprinting
4.7.3.1 LAB Setup
4.7.3.2 Advantages and Disadvantages
4.7.4 Stereolithography
4.7.4.1 The Setup for Stereolithography
4.7.4.2 Applications of Stereolithography
4.8 Challenges Faced by 3D Bioprinting Techniques
4.9 Conclusion
References
5. Powder Bed Fusion Process – State of Art
G. Rajesh Kannan, M. Sivakumar, B. Jagadeesh and N. S. Balaji
5.1 Introduction
5.2 Powder Bed Fusion (PBF)
5.2.1 Working Principle of PBF Process
5.2.2 Classification of Powder Bed Fusion Process
5.2.3 Process Parameters of Powder Bed Fusion Process
5.2.4 Effects of Heat in Powder Bed Fusion Process
5.3 Laser Powder Bed Fusion (L-PBF)
5.3.1 Why is the Term ‘Selective Laser Sintering’ Misleading?
5.3.2 Process Flow of L-PBF
5.3.3 Process Parameters for Laser Powder Bed Fusion
5.3.3.1 Laser Specifications
5.3.3.2 Component Parameters
5.3.3.3 Environment-Related Variables
5.3.4 The Impact of L-PBF Process Parameters on the Occurrence of Build Defects
5.3.5 Data Processing for Identification of Spatter-Related Issues
5.4 The Influence of L-PBF Processing Parameters on the Microstructure
5.5 Merits and Demerits of Powder Bed Fusion Process
5.5.1 Merits of Powder Bed Fusion
5.5.2 Demerits of Powder Bed Fusion
5.6 Applications of Powder Bed Fusion Process
5.7 Summary
References
6. Cobalt-Chromium Alloy Additive Manufacturing Technologies for Biomedical Applications
Pravin Pawar, Amaresh Kumar and Raj Ballav
6.1 Introduction
6.2 Selective Laser Melting (SLM) Additive Manufacturing
6.3 Laser Powder-Bed-Fusion (LPBF) Additive Manufacturing
6.4 Direct-Metal Laser-Sintering (DMLS) Additive Manufacturing
6.5 Selective Laser Sintering (SLS) Additive Manufacturing
6.6 Laser Melting (LM) Additive Manufacturing
6.7 Electron Beam Melting (EBM) Additive Manufacturing
6.8 Micro-Plasma Based Additive Manufacturing (MPBAM)
6.9 Direct Metal Fabrication (DMF) Additive Manufacturing
6.10 Wire and Arc Additive Manufacturing (WAAM)
6.11 Summary of Additive Manufacturing Technologies of Cobalt-Chromium Alloy Material for Bio-Medical Applications
6.12 Conclusion
References
7. Cold Spray Additive Manufacturing: Principles, Applications, and Recent Advancements
Jagadeesha T. and Sandip Kunar
7.1 Introduction
7.2 Literature Review
7.3 Phenomena and Factors Behind CSAM
7.4 Numerical Simulation of CSAM
Conclusion
Future Scope
References
8. Integrating Metal Forming and Additive Manufacturing for Enhanced Product Quality and Efficiency
Jagadeesha T. and Sandip Kunar
8.1 Introduction
8.2 Need of Additives in Metal Forming Process
8.3 Erichsen Test
8.4 Types of Additives
8.4.1 Slip Additives
8.4.2 Polymer Additives
8.4.3 Fluorinated Additives
8.4.4 Nanoparticle Additives
8.4.5 Hybrid Wire Arc Additive
8.4.6 Metal Additives
8.5 Effects of Additives in Various Processes
8.5.1 Impact of Slip Additive
8.5.2 Impact of Polymer Additives
8.5.3 Impact of Nano Additives
8.5.4 Impact of Metal Additives
8.5.5 Impact of Hybrid Wire – Arc Additive
8.6 Traditional Sheet Metal Forming and Additive Manufacturing
8.7 Technologies Used in Metal Forming That Involves Additives
8.8 General Impacts of Additives in Additive Manufacturing
8.8.1 Manufacturing Impacts
8.8.2 Environmental Impacts
8.8.3 Consumption of Energy
8.8.4 Environmental Risks
8.8.5 Affinity Towards Atmosphere Constituents
8.8.6 Thermal Conductivity and High Reflectivity
8.8.7 Residual Stress
8.9 Factors Affecting Additive Manufacturing
8.9.1 Surface Finish, Size, and Scaling of Geometry
8.9.2 Atmosphere of Build Chamber
8.9.3 Quality of Feedstock
8.9.4 Interactions Between Beam and Powder
8.9.5 Porosity
8.9.6 Swelling, Delamination and Cracking
8.9.7 Residual Stress
8.10 Conclusion
References
9. Impacts of Additives on Failure Issues Linked with Additively Manufactured Products
Jagadeesha T. and Sandip Kunar
9.1 Introduction
9.2 Additive Manufacturing
9.3 Technological Aspects
9.3.1 Impact of Additives in Manufacturing Processes
9.4 Challenges in Additive Manufacturing
9.5 Limitations and Future Scope
9.6 Conclusion
References
10. Nano-Additives for Advanced Additive Manufacturing: Enhancing Quality,
Sustainability and Performance
Jagadeesha T. and Sandip Kunar
10.1 Introduction
10.2 Application of Nano-Additives
10.3 Literature Survey
10.4 Methodology
10.4.1 Plasma Electrolytic Oxidation (PEO) for Mg and Its Alloys
10.4.2 Role of Nano-Additives in Piezoelectric Properties Enhancement of Potassium Sodium Niobate/Polyvinylidene Fluoride
10.4.3 Role of Nano-Additives in the Shape Retention Properties of 3D Printed Multibinder Geopolymer
10.4.4 Role of Nano-Additives in the Sintered TiC Ceramics
10.4.5 Role of Nano-Additives in UHPC Mix
10.4.6 Role of Nano-Additives in β-C2S Stabilization Purpose
10.4.7 Role of Nano-Additives in Zirconium Diboride UHTCs
10.5 LAM of the Titanium Carbide Nanoparticles Strengthened by Nickel Based Nano-Size Composites
10.6 Role of Nano-Additives to Enhance the Fuel Properties of Tyre Oil for Green Environment
10.7 Conclusion
References
11. Processing of Biomaterials by Additive Manufacturing
R. Prayer Riju, S. Arulvel, D. Dsilva Winfred Rufuss, Jayakrishna Kandasamy and P. Jeyapandiarajan
11.1 Introduction
11.2 Diverse Additive Manufacturing Techniques for Processing Biomaterials
11.2.1 Stereolithography (SLA)
11.2.1.1 SLA – Post-Processing
11.2.2 Fused Deposition Modelling (FDM)
11.2.2.1 Post-Processing of FDM Printed Biomaterial
11.2.3 Inkjet Printing
11.2.3.1 Post-Processing of Inkjet-Printed Biomaterial
11.2.4 Selective Laser Sintering (SLS)
11.2.4.1 Post-Processing of SLS Printed Biomaterial
11.2.5 Selective Laser Melting
11.2.5.1 Post-Processing of SLM Printed Biomaterial
11.2.6 Laser-Assisted Bio-Printing (LAB)
11.2.7 Direct Ink Writing (DIW)
11.2.7.1 Post-Processing of DIW Printed Biomaterial
11.3 Conclusion
References
12. Safety and Environmental Protection in Additive Manufacturing
N.S. Balaji, M. Sivakumar, G. Rajesh Kannan and R. Karthikeyan
12.1 Introduction
12.1.1 Environmental Sustainability Through Additive Manufacturing
12.1.2 Safety in Additive Manufacturing
12.2 Environmental Impacts of Additive Manufacturing
12.2.1 Embracing Sustainable Manufacturing
12.2.2 The Importance of Sustainability
12.2.3 Eco-Conscious Manufacturing
12.2.4 Waste Reduction and Resource Efficiency
12.2.5 Lean Manufacturing in a Competitive Market
12.3 Additive Manufacturing: A Sustainable Approach to Reducing Environmental Degradation
12.3.1 Advancements in Additive Manufacturing for Environmental Enhancement
12.3.1.1 Efficiency and Precision in Manufacturing
12.3.1.2 Customization and Innovation
12.3.1.3 Diverse Applications and Sustainability in Architecture
12.3.1.4 Environmental Benefits of AM
12.3.1.5 Positive Impact on Pollution Control
12.4 Developing a Sustainable Additive Manufacturing Ecosystem: Basic Building Blocks
12.4.1 Safety in Additive Manufacturing
12.4.2 Economic Features of AM
12.4.3 Environmental Sustainability in AM
12.4.4 Societal Impacts and Benefits
12.5 Enriching Sustainability Through Additive Manufacturing Processes: A Sequential Overview
12.6 AM Security and Safety: A Comprehensive Approach
12.6.1 AM Security and Safety: A Comprehensive Analysis
12.7 Summary
References
13. Advanced Developments in Additive Manufacturing of Silicone Rubber
Elastomers
Mohammad Bagher Jafari, Hossein Doostmohammadi, Mostafa Baghani and Majid Baniassadi
13.1 Introduction
13.2 Chemical Structure and Properties of Silicone Rubbers
13.2.1 Chemical Structure
13.2.2 Curing
13.3 Additive Manufacturing Techniques for Fabrication of Silicone Rubber Structures
13.4 3D Printable Silicone-Based Materials
13.4.1 Liquid Silicone Elastomer
13.4.2 Room Temperature Vulcanizing
13.4.3 High Consistency Silicone Rubber
13.5 Progress and Applications Proposed for 3D Printed Silicone Rubbers
13.5.1 Soft Robotics
13.5.2 Prosthetic Devices and Stents
13.5.3 Drug Delivery
13.5.4 Soft Electronics and Sensors
13.6 Challenges and Future Research Direction
13.7 Conclusion
References
14. Laser-Assisted Additive Manufacturing Techniques for Advanced Composites
Nitai Chandra Adak, Fahim Sharia and Wonoh Lee
14.1 Introduction
14.2 Classification of Laser-Based Additive Micromanufacturing Techniques
14.2.1 Selective Laser Sintering (SLS)
14.2.2 Direct Metal Laser Sintering (DMLS)
14.2.3 Selective Laser Melting (SLM)
14.2.4 3D Laser Printing Systems
14.2.4.1 Stereolithography Apparatus (SLA)
14.2.4.2 Digital Light Projection
14.2.4.3 Two-Photon Polymerization
14.2.4.4 Solid Ground Curing
14.3 Challenges in Laser-Based Additive Manufacturing of Composites
14.4 Conclusions and Future Research Opportunities
References
15. Stereolithography-Based Polymer Additive Manufacturing Process for Microfluidics Devices: A Review
Ajit Biswas, Amit Kumar Singh and Debasree Das
15.1 Introduction
15.1.1 Microfluidics: An Overview
15.1.2 Significance of Additive Manufacturing in Microfluidics
15.1.3 Novel Insights and Research Importance
15.1.4 Objective of the Review
15.2 Polymer Additive Manufacturing Processes
15.2.1 Material Extrusion
15.2.2 Binder Jetting
15.2.3 Polymer Powder Bed Fusion (P-PBF)
15.2.4 Vat Photopolymerization
15.3 Stereolithography (SLA) for Microfluidics
15.3.1 Working Principle and Process Flow
15.3.2 Suitable Polymers for SLA-Based Microfluidic Devices
15.3.2.1 Epoxy Resins
15.3.2.2 Polyurethane Resins
15.3.2.3 Acrylic Resins
15.3.2.4 Photopolymer Resins
15.3.2.5 Silicone Resins
15.3.2.6 Polyetherimide Resins
15.3.2.7 Polycarbonate Resins
15.3.3 Advantages and Limitations of SLA for Microfluidics Devices
15.3.4 Examples of SLA-Based Microfluidic Applications
15.4 Applications of Polymer Additive Manufacturing in Microfluidics
15.4.1 Biomedical Applications of Polymer Additively Manufactured Microfluidics Devices
15.4.1.1 Lab-on-a-Chip Devices for Diagnostics and Disease Monitoring
15.4.1.2 Lab-on-a-Chip Devices for Point-of-Care Diagnostics
15.4.1.3 Organ-on-a-Chip Platforms for Drug Screening and Personalized Medicine
15.4.1.4 Microfluidic Devices for Cell Culture and Tissue Engineering
15.5 Challenges and Future Prospects of Polymer Additive Manufacturing Processes in Microfluidics
15.6 Conclusion
References
16. Biomaterials and Bioinks: A Synergistic Approach to Bioprinting
M. Abdur Rahman, G. Rajesh and N. Sri Rangarajalu
16.1 Introduction
16.1.1 Bioprinting
16.1.1.1 Drug Delivery Systems
16.2 Bioprinting
16.2.1 The Process of 3D Bioprinting Involves Several Key Steps
16.2.1.1 Bioink Formulation
16.2.1.2 Key Aspects that Highlight the Importance of Bioinks
16.3 Extrusion-Based Bioprinting
16.3.1 Benefits of Extrusion-Based Bioprinting
16.3.1.1 The Main Elements of Extrusion-Based Bioprinting
16.3.1.2 Applications of Extrusion-Based Bioprinting
16.4 Inkjet-Based Bioprinting
16.4.1 Inkjet-Based Bioprinting Has Several Advantages
16.5 Significant Aspects of Bioprinting
16.5.1 Bioprinting in Regenerative Medicine
16.5.1.1 Bioprinting for Implants and Medical Devices
16.5.1.2 Important Moral and Legal Issues with Bioprinting
16.5.1.3 New Developments in 3D Bioprinting of Complicated Organs and Tissues
Conclusion
References
17. Significance of Additive Manufacturing in Aerospace and Automotive Industries
M. Abdur Rahman, Ravi Kumar S. and A.S. Selvakumar
17.1 Introduction to Additive Manufacturing (AM) in the Aerospace and Automotive Industry
17.2 AM Processes in the Aerospace Industry
17.3 AM Processes in the Automotive Industry
17.4 AM Applications of Automotive and Aerospace Industries
17.4.1 AM’s Applications in the Automotive Industry
17.4.2 Aerospace Applications of AM
17.5 Material Selection in AM
17.6 DfAM in Aerospace Applications and Automotive Applications
17.7 Supply Chain and Manufacturing Integration in the Aerospace Industry
17.8 Supply Chain and Manufacturing Integration in the Automotive Industry
17.9 Maintenance, Repair, and Overhaul (MRO) in Aerospace AM
17.10 Maintenance, Repair, and Overhaul (MRO) in Automotive AM
17.11 Circular Economy in the Aerospace Industry
17.12 Circular Economy in the Automotive Industry
17.13 Conclusion
17.14 Future Scope
References
18. Sustainability and Efficiency: The Green Potential of Additive Manufacturing
M. Abdur Rahman, Serajul Haque, N. Sri Rangarajalu and D. R. Rajendran
18.1 Introduction to Additive Manufacturing (AM) and Its Role in Sustainability
18.1.1 Key Principles of Additive Manufacturing
18.1.1.1 Historical Development and Growth of AM in Various Industries
18.2 The Relevance of AM in the Context of Sustainability and Efficiency
18.2.1 Environmental Impact Assessment
18.2.2 Consumption of Resources
18.2.2.1 Traditional Manufacturing’s Energy Consumption
18.3 Life Cycle Assessment (LCA) of AM Processes and Products
18.4 Identification of Key Environmental Hotspots in AM Technology
18.5 Sustainable Materials and Additive Manufacturing
18.5.1 Exploration of Sustainable Materials for AM
18.6 Biodegradable and Recycled Materials in AM
18.7 The Potential for Renewable Energy Integration in AM Processes
18.8 Waste Reduction and Circular Economy in Additive Manufacturing
18.8.1 Strategies for Minimizing Waste in AM
18.8.2 Eco-Friendly Alternatives in Additive Manufacturing
18.9 Research and Development Areas to Enhance AM’s Green Potential
18.9.1 Potential Challenges and Opportunities in the Future of Green AM
18.10 Conclusion
18.10.1 Future Prospects: Green Potential of AM
References
19. Role of Additive Manufacturing in IoT Medical Devices
K. Vijetha, Uzwalkiran Rokkala and Lingaraju Dumpala
19.1 Introduction
19.2 Additive Manufacturing
19.2.1 Additive Manufacturing for Medical Devices
19.2.2 Benefits of 3D Printing
19.2.3 Additive Manufacturing (AM) with Internet of Things
19.3 Future Scope for IoT
19.4 Conclusions
References
20. Additive Manufacturing of Superhydrophobic Architectures
Hossein Doostmohammadi, Majid Baniassadi and Mostafa Baghani
20.1 Introduction
20.2 Principles of Superhydrophobicity of Structures
20.2.1 Wettability, Surface Tension, and Contact Angle
20.2.2 Wenzel and Cassie-Baxter Regimes
20.3 Additive Manufacturing Techniques and Methods for Creation of Superhydrophobic Surfaces
20.3.1 Two Photon Polymerization 3D Printing
20.3.2 Stereolithography
20.3.3 Selective Laser Sintering
20.3.4 Digital Light Processing
20.3.5 Fused Deposition Modeling
20.3.6 Other 3D Printing Techniques
20.4 Advantages and Disadvantages of 3D Printing Techniques
20.5 Conclusion, Challenges, and Future Outlook
References
21. Fiber-Reinforced Composite and Topology Optimization in Additive Manufacturing
Tien-Dat Hoang and Van Du Nguyen
21.1 Introduction
21.2 Printed Model Without Fiber Reinforcement
21.2.1 3D Model and Material Properties
21.2.2 Printing Lattice Settings
21.2.3 Simulation and Experiment Results
21.2.3.1 Simulation Setting
21.2.3.2 Experiment Settings
21.2.3.3 Comparison Between Simulation and Experiment Results
21.3 Printed Model with Continuous Fiber Reinforcement
21.3.1 3D Printing Model
21.3.2 Tensile Simulation for Predict Stiffness and Deformation
21.4 Printing Model Integrating Topology Optimization and Continuous Fiber Reinforcement
21.4.1 Level Set-Based Multi-Material Topology Optimization
21.4.2 Topological Design Procedure
21.5 Conclusion
Acknowledgement
References
22. Comparative Analysis of Mechanical Characteristics in Additive Manufacturing on Polylactic Acid and Acrylonitrile Butadiene Styrene Materials
Kaustubh Pravin Joshi and Anil Dube
22.1 Introduction
22.2 Literature Review
22.3 Experimental Setup
22.3.1 Process
22.3.2 Testing
22.4 Results and Discussion
22.5 Conclusion
References
23. A Comprehensive Review on Polymers and Metal Additive Manufacturing
Praveena B. A., Santhosh N. and Anand G.
23.1 Introduction
23.2 Additive Manufacturing Processes and Methods
23.2.1 Fundamental Principles
23.2.2 Key Processes and Techniques in Polymer Additive Manufacturing
23.2.3 Key Processes and Techniques in Metal Additive Manufacturing
23.3 Materials for Additive Manufacturing
23.4 Additive Manufacturing Applications
23.4.1 Applications in Polymers Additive Manufacturing
23.4.2 Applications in Metal Additive Manufacturing
23.5 Challenges and Limitations
23.6 Future Directions and Opportunities
23.7 Conclusion
References
24. Sub-Zero Additive Manufacturing: A Green Solution to Pattern Making in the Investment Casting Industry
Pushkar Kamble, K. P. Karunakaran and Yicha Zhang
24.1 Introduction
24.2 Process of Using Ice Patterns by Sub-Zero Additive Manufacturing
24.2.1 Case Study 1
24.2.2 Case Study 2
24.3 Economic Comparison
24.4 Conclusions
24.5 Future Scope
References
25. Effect of Orientation on the Tensile Strength of 3D Printed Rectangular Solid Bars
Neel Kamal Gupta and Pawan Kumar Rakesh
25.1 Introduction
25.2 Modelling and Simulation
25.2.1 CAD Modelling
25.2.2 Material Properties
25.2.3 Modelling of Rectangular Solid Bar
25.3 Manufacturing of Rectangular Solid Bar by PolyJet Printing Technology
25.3.1 Manufacturing of Rectangular Solid Bar by FDM Technology
25.3.2 Tensile Test of Rectangular Solid Bar
25.4 Design of Experiment
25.5 Selection of Process Parameters
25.6 Selection of Orthogonal Array
25.7 Conclusion and Future Scope
References
26. Advanced Techniques in Wire Arc Additive Manufacturing: Monitoring, Control, and Automation
M. Sivakumar, R. Karthikeyan, N.S. Balaji and G. Rajesh Kannan
26.1 Introduction
26.2 Wire Arc Additive Manufacturing
26.2.1 Introduction to Wire Arc Additive Manufacturing
26.2.2 Principle of Mechanism
26.2.3 Advantages and Challenges of WAAM
26.3 Defects in the WAAM Process
26.4 Sensing Technology in Additive Manufacturing and Challenges in WAAM
26.4.1 Difficulties in Sensing Methods for Wire Arc Additive Manufacturing
26.4.2 Vision Sensing
26.4.3 Spectral Sensing
26.4.3.1 Spectral Sensing in WAAM
26.4.4 Acoustic Sensing
26.4.5 Thermal Sensing
26.5 Quality Control Strategies for WAAM
26.6 Automation in Wire Arc Additive Manufacturing
26.6.1 Automation Methods in WAAM
26.7 Case Study: Implementing a Closed-Loop Multiple Sensors System for Quality Control in the WAAM Process
26.7.1 The Challenge
26.7.2 Closed-Loop Control System
26.7.2.1 Three-Step Closed-Loop System
26.7.2.2 Quality Control Strategy
26.7.3 Solution of Case Study
26.7.4 Implementation and Results
Summary
References
27. Vat Photopolymerization
J. Suresh Kumar, Akshaya Senthilkumar, S. Naveen Rajkumar and K. Kalaichelvan
27.1 Introduction
27.2 Vat Polymerization Process
27.2.1 Pre-Building Process
27.2.2 Post-Building Process
27.2.3 Materials
27.3 Vat Polymerization Techniques
27.3.1 Stereolithography (SLA)
27.3.2 Digital Light Processing (DLP)
27.3.3 Continuous Digital Light Processing (CDLP)/Continuous Liquid Interface Production (CLIP)
27.3.4 Two-Photon Polymerization (2PP)
27.3.5 Liquid Crystal Display–Stereolithography (LCD–SLA)
27.4 Photoinitiator Materials
27.4.1 Radical Mechanism of Chain Growth
27.4.2 Cationic Mechanism of Chain Growth
27.5 Applications
27.5.1 Medical Applications
27.5.2 Mechanical Applications
27.5.3 Other Applications
References
Index
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