Additive manufacturing, also known as 3D printing, is not a new concept. In fact, the earliest prototypes were successfully created in the 1980s. But 3D printing is more than just a novel production method. It offers a revolutionary approach for complex discrete manufacturers who prioritize precision and efficiency overall.
Additive manufacturing is redefining production lines. Understanding the nuances of these methods is the first step in leveraging them.
Simply put, additive manufacturing is the process of making three-dimensional solid objects from a digital file. It involves adding material layer by layer, which is why it is called additive. You can often tell when something is created with a 3D printer since you can see the thin layers.
The opposite of additive manufacturing is subtractive manufacturing. As the name suggests, this method removes materials from a solid block to create a final product. It creates a seamless and durable product but ultimately wastes a significant amount of material.
Additive manufacturing is much more material-efficient and can produce shapes and structures that traditional methods cannot. The designs for additive manufacturing are made possible by 3D modeling software and advanced materials that can be tailored to the printing needs.
Additive manufacturing 3D printing is especially beneficial for complex discrete manufacturers. These manufacturers must always prioritize precision and customization, all while managing costs. This is no small feat.
Additive manufacturing offers solutions to each of these challenges:
There’s no one-size-fits-all approach to additive manufacturing. That’s because each type uses different materials, unique layering, and distinct additive manufacturing technologies. Here are the most common types of additive manufacturing production techniques that can support your operations.
Also known as Vat Polymerization, this is one of the oldest types of additive manufacturing. It uses an ultraviolet laser to cure and solidify photopolymer resin in a vat layer by layer, building the object from the bottom up.
It’s typically used to create highly detailed prototypes or custom anatomical models and surgical guides.
This technique is part of the Power Bed Fusion process. It involves the use of a high-power laser to fuse small particles of polymer powder into a solid structure. The laser selectively fuses powdered material by scanning cross-sections generated from a 3D digital description of the part.
The powder acts as its own support, which allows for the creation of complex parts and shapes. It’s ideal for creating prototypes for automotive and aerospace manufacturers due to its durability.
Also called material extrusion, FRM works by extruding thermoplastic filaments through a heated nozzle, melting and depositing them layer by layer. The material hardens immediately after extrusion as it cools.
It’s typically more cost-effective and accessible, though it may not be as durable.
This is likely what you think of when it comes to 3D printing. The machine jets layers of liquid photopolymer onto a build tray and cures them using UV light. This process is repeated, building up layers of the object until completion. It can use multiple materials within a single print and is relatively fast.
Envision a print head moving across a bed of powder material, selectively depositing a liquid binding agent in the shape of the section to be built. After each layer, a new layer of powder is spread over the previous one, and the process repeats until the part is complete.
This fairly complex type of additive manufacturing involves feeding metal powder or wire into a melt pool created by a high-energy beam. The material is melted and solidified to form layers of the object. It’s commonly used to repair high-value parts.
Wire arc additive manufacturing is under this umbrella, since it uses an electrical arc as a source of fusion.
As the name suggests, LOM involves layers of adhesive-coated paper, plastic, or metal laminates being successively glued together and cut to shape with a knife or laser cutter. It’s one type of metal additive manufacturing that can be made rapidly, albeit not very detailed.
Additive manufacturing is made even more efficient with the right modern manufacturing software at your fingertips. Learn more about how First Resonance supports additive manufacturing like 3D printing. Schedule a demo today.