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Additive Manufacturing
“a process of joining materials to make objects from 3D
model data, usually layer upon layer…”
- ASTM Standard F2792-12a
• Material extrusion
• Material jetting
• Binder jetting
• Vat photopolymerisation
• Sheet lamination
• Powder bed fusion
• Directed energy deposition
dupress.com/articles/additive-manufacturing-3d-opportunity-in-aerospace/
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Additive Manufacturing
1985-1990 2000-2010 2010+
• Plastics • Metals ‘printing’ emergence • Metals printing
• metal sintering • Commercialization of 3D commercialization
printing technology • Production-grade
metallic parts sought
www.am.msstate.edu
Material Extrusion
• Fused filament fabrication, Fused deposition
modeling, 3D printing
• Stratasys®, MakerBot®
• Thermoplastics, nylon
• < 570 ºF, heated nozzle (liquid on delivery)
• Home, office or industry
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Material Jetting
• Drop-on-demand, 3D printing
• Similar to inkjet, 2D printing
• Liquid photopolymer that is cured
• Home, office or industry
http://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing/materialjetting/
www.am.msstate.edu
Sheet Lamination
• Ultrasonic additive manufacturing,
laminated object manufacturing
• Sheets/ribbons of material bound via
ultrasonic welding
• Low-temperature
• Non-structural parts
http://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing/sheetlamination/
http://www.insidemetaladditivemanufacturing.com/blog/ultrasonic-additive-manufacturing
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Additive Manufacturing of Metals
Selective
Direct Laser
Laser Melting
Deposition
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Additive Manufacturing of Metals: Large Potential
• Customize parts for specific applications
• Biomedical implants, heat exchangers
• Fabricate complex geometries
• Repair expensive parts
• Manufacture in remote locations
• Submarines, battlefield, ships, space
• Reduce weight and cost of parts
• Aerospace
• Potential economic rewards:
• New skilled jobs created in U.S.
• Restored U.S. strength in manufacturing
• Trade deficit reduction
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Additive Manufacturing of Metals: The Bottleneck
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Additive Manufacturing: Trending
blog.purisllc.com/blog
10
Economic Growth
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Biomedical Applications in Additive Manufacturing
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Facilities at MSU/CAVS
Direct Laser Deposition (DLD)
Donated by Army c. 2006
OPTOMEC LENS 750 w/ 1 kW laser and multi-
camera thermal monitoring
Multi-powder feeder for functional-grading
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Advanced Laser-Based Additive Manufacturing… Our Approach
The Complexity of Additive Manufacturing
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Mechanical Testing of Additive-Manufactured Parts
Strain Life Curve: Wrought & LENS Ti-6Al-4V
Sterling, A.J., Torries, B., Lugo, M., Shamsaei, N., Thompson, S.M., 2015, “Fatigue Behavior of Ti-6Al-4V Alloy Additively Manufactured by Laser
Engineered Net Shaping,” 56th AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference Kissimmee, FL. || DOI:
10.2514/6.2015-1354.
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Thermal Monitoring and Control
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Dual Thermal Monitoring of LENS
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Porosity & X-Ray Computed Tomography
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Simulation via High Performance Computing at MSU
deposited track
powder bed
substrate
Fluid dynamics, solidification, high heat flux diffusion,
microstructural evolution
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Additive Manufacturing at Mississippi State
National leadership
Organizing joint workshop with ASTM & NIST in
2016
Organizing ASME’s Symposium on Additive
Manufacturing
MSU is leading certification efforts AM parts
with Federal Aviation Administration (FAA)
MSU Faculty serving as Guest Editors of Special
Issue in Additive Manufacturing
ASTM Representative on U.S. National
Committee on Theoretical and Applied
Mechanics: Supervisory Role in Additive
Manufacturing
CAVS is now a member of ‘America Makes’
Sponsored AM research projects from NSF,
NASA, Army and industry
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Thanks!
Questions?
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