3-D Printing Principles, Processes, and Applications

In 3-D Printing Principles, Processes, and Applications, you'll learn ...

• Types of polymer and metal 3-D printing processes
• Principles, advantages and disadvantages, materials, and applications of each process
• The benefits and limitations of 3-D printing and each process
• Post-processing requirements for optimal mechanical properties and surface finishes

Overview

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Credit: 5 PDH

Length: 58 pages

Three-dimensional (3-D) printing or additive manufacturing is the process of taking 3-D drawings from computer-aided design (CAD) files and making 3-D solid objects from polymers, ceramics, composites, and metals. The creation of the solid object is an additive process that prints the object layer-by-layer. This process is inherently opposite to the subtractive processes of CNC-machining, cutting, drilling, and grinding. It is also different than formative manufacturing technologies such as casting or injection molding.

Today, 3-D printing and subtractive processes are used in tandem. 3-D printing integrates 3-D design and modeling, materials, and manufacturing. Hence, a major benefit of 3-D printing is that it can produce geometrically complex shapes at a much lower cost than conventional methods. On the other hand, 3-D printed components require post-processing for optimal mechanical properties and surface finishes and may have lower accuracy and tolerances than conventional methods. It is for this reason that subtractive processes are often used in conjunction with 3-D printing.

In this course, we will first cover the interesting early history of 3-D printing starting in 1981. We then consider polymer 3-D printing processes, including Fused Deposition Modeling (FDM), Stereolithography (SLA), and Selective Laser Sintering (SLS). This is followed by a discussion of metal 3-D printing processes, including two powder bed fusion methods of Direct Metal Laser Sintering (DMLS) and the functionally very similar Selective Laser Melting (SLM), powder Directed Energy Deposition (DED), and Binder Jetting.

In the appropriate sections, we discuss other 3-D printing techniques that are similar to the aforesaid ones. We discuss the principles, advantages and disadvantages, materials, and applications of each process. We consider post-processing at various points in the text. Next, we examine the principles of 3-D printing, including 3-D solid models, slicing of the CAD model, and design considerations and challenges. In the final section, we discuss different materials that are commonly printed. We discuss the benefits and limitations of 3-D printing and each process in the text.

Learning Objectives

Upon completion of this course, participants will be able to:

• Describe common polymer 3D-printing processes, including fused deposition modeling (FDM), stereolithography (SLA), and selective laser sintering (SLS).
• Explain common metal 3D-printing processes, including direct metal laser sintering (DMLS), directed energy deposition (DED), and binder jetting.
• Identify other polymer and metal 3D-printing processes and recent developments.
• Explain 3D-model types, modeling software, model repositories, .stl files, slicing, and G-Code.
• Compare 3D-scanning methods, including coordinate measuring machines, laser scanning, structured light scanning, photogrammetry, and industrial CT scanning.
• Describe 3D-printing design considerations and challenges, including overhangs, wall thickness, minimum feature size, tolerances, build orientation, warping, delamination, and porosity.
• Distinguish among common thermoplastics used in 3D printing, including PLA, ABS, PETG, nylon, and PEEK.
• Describe thermoset engineering resins used in 3D printing.
• Explain gas atomization, titanium alloys, steels, and aluminum alloys in the context of 3D printing.

Certificate of Completion

You will be able to immediately print a certificate of completion after passing a multiple-choice quiz consisting of 25 questions. PDH credits are not awarded until the course is completed and quiz is passed.