Types of Additive Manufacturing

Enterprises from various industries have been switching from subtractive manufacturing to additive manufacturing to curtail production time and cost significantly. As its name indicates, additive manufacturing or additive layer manufacturing produces a variety of three-dimensional objects physically by adding materials layer by layer through a computer-controlled process.

According to AdditiveManufacturing.media, “’ Additive manufacturing’ (AM) describes the use of 3D printing to make functional components, including tools and end-use production parts. Unlike ‘subtractive manufacturing’ such as processes machining, where parts are created by removing material, additive manufacturing builds geometries by ‘adding’ feedstock such as filament, wire or powder.” Additive manufacturing produces solid parts, models, prototypes, and products by leveraging 3D printing. 3D printing technologies produce various objects from three-dimensional digital models by adding materials or filaments layer by layer. In addition to reducing material consumption and wastage, additive manufacturing enables you to produce parts with complex geometries and varying shapes.

You also have the option to choose from different types of additive manufacturing according to the precise project needs. Likewise, you can use additive manufacturing technologies to produce objects using a variety of materials – powder, resins, and plastics. That is why; you should understand and compare some of the widely used additive manufacturing technologies to streamline the manufacturing process.

Brief Overview of 7 Widely Used Additive Manufacturing Technologies

1. Binder Jetting:

Binder jetting technique creates parts by joining powder material using a binder or binding liquid during the fusion process. You have to choose the appropriate binder or binding liquid according to the type of powder used in the additive manufacturing process. This type of additive manufacturing allows you to choose from various types of materials – ceramics, metal, and polymer. Also, you can make the object appealing by adding a wide range of colors. But you need to put extra time and effort into post-processing activities. Also, you cannot use this type of additive manufacturing to build structural parts with strength and accuracy.

2. Material Extrusion:

This popular form of additive manufacturing builds objects by depositing thermoplastic or composite filament continuously. These industrial 3D printers are designed with extruding nuzzles through which the thermoplastic filament is fed. The machine uses heat to fuse the filament deposited on the build platform layer by layer. Many enterprises opt for material extrusion as an easy-to-use and user-friendly additive manufacturing technology. Material extrusion allows you to build objects using a variety of print materials without escalating material costs. But this technique requires support. Also, it is not effective in producing strong and durable parts.

3. Material Jetting:

This type of additive manufacturing builds three-dimensional objects by depositing droplets of wax-like materials selectively onto the build platform. The wax-like material is deposited in layers on top of each other. The part is formed as the material becomes cool and solid gradually. The printed object is produced after the support structure is removed or melted. Enterprises opt for material jetting technology while producing parts with superior surface finishing and outstanding accuracy. But wax-like material often makes the printed item fragile. Also, you do not have the option to choose from a wide range of wax-like materials for this additive manufacturing process.

4. Powder Bed Fusion:

The powder bed fusion method builds parts by melting plastic or metal powder particles using a variety of energy sources. The energy source melts the powder which is subsequently fused and solidified to create the pattern. This category of 3D printers is developed with two build chambers and a creating roller. While using powder bed fusion technology, you have the option to choose from and combine a variety of materials. Also, you can 3D-print industrial items with minimal support. But the additional post-processing increases the additive manufacturing time significantly. Also, this additive manufacturing technology is suitable for creating objects with weak structural properties and varying surface textures.

5. Sheet Lamination :

As the name indicates, the sheet lamination method produces objects by stacking and laminating multiple and thin layers of materials using a variety of ways – bonding, brazing, or ultrasonic welding. You need to use a CNS or laser cutting machine to form the final shape of the object. Sheet lamination is one of the fast and cost-efficient additive manufacturing methods. It enables you to manage materials effortlessly without providing support structures. But you must arrange a larger working area and spend additional time on post-processing activities. You do not have the option to choose from a wide range of materials while using sheet lamination techniques. You need to use the appropriate sheet lamination technique to achieve the desired bonding strength.

6. Directed Energy Deposition

Direct energy deposition creates three-dimensional objects by melting wire-based or powder-based printing material using a variety of energy sources – laser, plasma arc, and electronic beams. Enterprises these days use the direct energy deposition method to facilitate hybrid manufacturing. Also, this type of additive manufacturing is used widely to create items with complex shapes using metal, ceramic, or polymer. In addition to accelerating the additive manufacturing process, the direct energy deposition method is effective in building large, strong, and dense parts. But you need to incur high capital expenditure to streamline the additive manufacturing process.

7. Vat Photopolymerization

The vat photopolymerization method creates three-dimensional items by converting photopolymer liquid resin into hard plastic. It cures the photopolymer liquid resin in a vat layer by layer using an ultraviolet laser. Enterprises opt for this form of additive manufacturing to create large items with optimal accuracy and superior finish. This method created parts in a shorter amount of time. But you lack the option to choose from a variety of photopolymer liquid resins. Also, you have the put extra time and effort to remove additional resin during the post-processing. Vat photopolymerization is one of the more expensive additive manufacturing technologies. While considering and comparing various types of additive manufacturing, you must not ignore some of the widely used 3D printing technologies. Both 3D printing and additive manufacturing technologies build solid objects depositing materials or filaments layer by layer based on CAD files. But additive manufacturing technologies are more advanced and rigorous than 3D printing technologies.

About Aurum3D Aurum3D is one of the leading 3D printing companies in Bangalore. We have been working in multiple technologies of 3D printing like FDM, SLA, and SLS 3D Printing in areas like prototyping and custom 3D printing.

References:

https://www.k3syspro.com/advice-centre/erp-advice/whats-the-difference-between-3d-printing-and-additive-manufacturing/

https://www.additivemanufacturing.media/articles/additive-manufacturing-and-3d-printing-are-two-different-things

https://additivemanufacturing.com/basics/

https://www.additivemanufacturing.media/kc/what-is-additive-manufacturing

https://www.appliedengineering.com/blog/2021/1/22/7-types-of-additive-manufacturing

https://blog.spatial.com/types-of-additive-manufacturing

https://www.firetrace.com/fire-protection-blog/additive-manufacturing