Additive Manufacturing: A Tool for Industrial Revolution 4.0

Front Cover
Additive Manufacturing: A Tool for Industrial Revolution 4.0
Copyright Page
Contents
List of contributors
Preface
1 Additive manufacturing: a thrive for industries
1.1 Introduction
1.2 Additive manufacturing technology
1.2.1 Polymerization technique: stereolithography
1.2.1.1 Reprocessability in stereolithography
1.2.2 Sintering technique
1.2.2.1 Reprocessability in sintering: in selective laser melting
1.2.3 Material jetting techniques and fused deposition modeling
1.3 Additive manufacturing and supply chain 4.0
1.3.1 Hypothetical case study on 3D-printed pharmaceutical pills
1.4 Additive manufacturing: a postpandemic or endemic view
1.5 Conclusion
References
2 Basic principles of additive manufacturing: different additive manufacturing technologies
2.1 Introduction
2.2 Types of additive manufacturing techniques
2.2.1 Direct additive manufacturing techniques
2.2.1.1 Stereolithography
2.2.1.2 Fused deposition modeling
2.2.1.3 Polyjet technology
2.2.1.4 Laminated object manufacturing
2.2.1.5 Selective laser melting
2.2.1.6 Electron beam melting
2.2.1.7 Laser-engineered net shaping
2.2.1.8 Three-dimensional printing
2.2.1.9 ProMetal (binder jetting)
2.2.2 Indirect additive manufacturing techniques
2.2.2.1 Casting patterns with additive manufacturing
2.2.2.2 Direct additive manufacturing of molds
2.3 Application of additive manufacturing technologies
2.3.1 Comparison between additive manufacturing process and traditional manufacturing process
2.4 Future research directions in additive manufacturing technology
References
3 Developments in additive manufacturing
3.1 Introduction to the additive manufacturing process
3.1.1 The evolution of 3D printing
3.1.2 Design for additive manufacturing
3.2 User benefits of additive manufacturing
3.2.1 Cost competitiveness
3.2.2 Technologies development
3.3 Additive manufacturing timeline
3.4 Forecast of 3D printing growth in Industrial Revolution 4.0
3.4.1 Industrialization of 3DP technology
3.4.2 Manufacturing business technology
3.4.3 File formats
3.4.3.1 STL
3.4.3.2 OBJ
3.5 Material developments in additive manufacturing
3.6 Metal 3D Printers
3.7 International scenario
3.8 Summary
References
4 Review on 3D printing of medical parts
4.1 Introduction of medical 3D printing
4.2 Reverse engineering of medical parts
4.3 Applications of 3D printing in the medical field
4.4 3D printing processes
4.4.1 Stereolithography
4.4.2 Selective laser sintering/selective laser melting
4.4.3 Fused deposition modeling
4.4.4 Inkjet-based bioprinting
4.5 Healthcare applications of 3D printing materials
4.5.1 Metals and its alloys
4.5.2 Bioceramics and bioactive glasses
4.5.3 Polymers
4.5.4 Bioinks
4.6 Regulatory challenges in 3D printing
4.6.1 Design controls
4.6.2 Build process
4.6.3 Postproduction
4.6.4 Clinical data
4.7 Summary
References
5 Software interface issues in consideration of additive manufacturing machines and processes
5.1 Introduction
5.2 Terms used in stereolithography file
5.3 Stereolithography file configuration
5.4 How layers are computed?
5.5 Support structures
5.6 Problems issues associated with the stereolithography files
5.7 Stereolithography file manipulation
5.8 Benefits of stereolithography file generation using the additive manufacturing machines
5.9 The additive manufacturing file format
References
6 Role of additive manufacturing in the era of Industry 4.0
6.1 Introduction
6.2 The basic working principle of additive manufacturing
6.3 Classes of additive manufacturing
6.3.1 Vat photo polymerization
6.3.2 Binder jetting process
6.3.3 Material jetting
6.3.4 Powder bed fusion
6.3.5 Material extrusion
6.3.6 Sheet lamination
6.3.7 Directed energy deposition
6.4 Areas of application of additive manufacturing
6.4.1 Medical
6.4.2 Automobile industry
6.4.3 Aerospace industry
6.4.4 Architecture
6.5 Additive manufacturing as a tool for Industry 4.0
6.6 Summary
References
7 Perspectives on additive manufacturing in Industry 4.0
7.1 Introduction
7.2 Manufacturing systems
7.3 Additive manufacturing and Industry 4.0
7.4 Adaption of additive manufacturing in industry: challenges and the way ahead
7.4.1 Throughput
7.4.2 Accuracy
7.4.3 Surface roughness
7.4.4 Quality
7.4.5 Efficiency
7.5 Adaption of Industry 4.0 in industry
7.6 Digital thread and additive manufacturing
7.7 Traditional versus direct digital manufacturing
7.8 Internet of Things and additive manufacturing
7.9 Big data and additive manufacturing
7.10 Edge computing
7.11 Fog computing
7.12 Cloud computing
7.13 Automation and additive manufacturing
7.14 Robots in additive manufacturing
7.15 Digital twin in Industry 4.0
7.16 Artificial intelligence in additive manufacturing
7.17 Digitally augmented part
7.18 Sustainability with additive manufacturing in Industry 4.0
7.19 Manufacturing scenario with additive manufacturing in Industry 4.0
7.20 Quality, qualification, and certification of additive manufacturing products with Industry 4.0
7.21 Transformation to IIoT based additive manufacturing
7.22 Manufacturing scenario with additive manufacturing and Industry 4.0
7.23 Future factory with Industry 4.0 and additive manufacturing
7.23.1 Sequence of operations in a smart factory equipped with additive manufacturing and Industry 4.0 technologies
7.24 Conclusion
References
8 Additive manufacturing of titanium alloys: microstructure and texture evolution, defect formation and mechanical response
8.1 Additive manufacturing of titanium alloys
8.2 Microstructure evolution in additive manufacturing
8.2.1 Grain morphology
8.2.2 Phase formation
8.2.3 Spheroidization of α phase
8.3 Crystallographic texture evolution in additive manufacturing
8.3.1 Macrotexture formation
8.3.2 Variant selection
8.3.3 Microtexture formation and macrozone elimination
8.3.4 Grain morphology and texture transition at the interface
8.4 Defect formation in additive manufacturing
8.4.1 Residual stresses
8.4.2 Porosity formation
8.5 Mechanical properties of additively manufactured parts
8.5.1 Effect of microstructure
8.5.2 Effect of texture
8.5.3 Effect of defects
8.6 Summary
References
9 Wire arc additive manufacturing: approaches and future prospects
9.1 Introduction
9.2 Process history
9.3 Process essentials
9.4 Variants of arc-based additive manufacturing process
9.5 Materials
9.6 Modeling and simulation
9.7 Postprocessing/heat treatment
9.8 Benefits and future challenges
9.9 Conclusion
References
10 Materials for additive manufacturing and 4D printing
10.1 Materials for additive manufacturing
10.2 Types of materials used for plastic/polymer printing
10.3 Types of materials used for metal 3D printing
10.4 Materials for bioapplications
10.5 Engineering properties of materials
10.6 Issues and challenges of materials in additive manufacturing
10.7 What is 4D printing?
10.8 Material selection for 4D printing
10.8.1 Thermoresponsive materials
10.8.2 Moisture responsive materials
10.8.3 Photo/electro/magnetoresponsive materials
10.9 Advantages and applications of 4D printing
10.9.1 Advantages
10.9.1.1 Size changing
10.9.1.2 New materials equal to new properties
10.9.2 Potential applications of 4D printing
10.9.2.1 Self-repair piping system
10.9.2.2 Self-assembly furniture
10.9.2.3 Medical industry
10.9.2.4 Fashion
References
Further reading
11 Polymeric materials for three-dimensional printing
11.1 Biopolymers for three-dimensional printing
11.1.1 Alginate-based three-dimensional printed materials
11.1.2 Chitosan-based three-dimensional printed materials
11.1.3 Starch and starch blends
11.1.4 Three-dimensional printing cellulose and its derivatives
11.1.5 Proteins for three-dimensional printing
11.2 Synthetic polymers for three-dimensional printing
11.2.1 Polyolefins for three-dimensional printing
11.2.2 Elastomers
11.2.3 Fluoropolymers
11.2.4 Three-dimensional printing using poly(lactic acid)
11.3 Conclusions
Acknowledgments
References
12 In situ monitoring of metal additive manufacturing process: a review
12.1 Introduction
12.2 Common defects in metal AM and recommended monitoring method
12.3 Powder bed fusion processes
12.3.1 Levels in powder bed fusion process
12.3.1.1 Melt pool and track
12.3.1.2 Slice and entire build
12.3.1.3 Powder bed
12.3.2 Coaxial sensing for melt pool monitoring of selective laser melting
12.3.2.1 Vision and thermal based (visible and infrared range)
12.3.2.2 Inline coherent imaging technique
12.3.3 Off-axial camera setup for monitoring of the entire layer in the PBF process
12.3.3.1 Vision and thermal based (cameras and pyrometers)
After powder deposition before fusion of a new layer
During the scanning of each slice
After the scan
12.3.3.2 3D vision (fringe projection) technique
12.4 Direct metal deposition
12.4.1 Powder feed
12.4.2 Wire feed
12.5 Sensors predominantly used for in situ monitoring of AM process
12.5.1 Optical tomography
12.5.2 Internal inspection through X-ray imaging and CT Scan
12.5.3 Other nondestructive sensors
12.6 Quality challenges in additive manufacturing
12.7 Conclusion
References
Index
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