Skip to main content
Workforce LibreTexts

2: Core AM Technologies and Supporting Processes

  • Page ID
    46508
  • \( \newcommand{\vecs}[1]{\overset { \scriptstyle \rightharpoonup} {\mathbf{#1}} } \)

    \( \newcommand{\vecd}[1]{\overset{-\!-\!\rightharpoonup}{\vphantom{a}\smash {#1}}} \)

    \( \newcommand{\id}{\mathrm{id}}\) \( \newcommand{\Span}{\mathrm{span}}\)

    ( \newcommand{\kernel}{\mathrm{null}\,}\) \( \newcommand{\range}{\mathrm{range}\,}\)

    \( \newcommand{\RealPart}{\mathrm{Re}}\) \( \newcommand{\ImaginaryPart}{\mathrm{Im}}\)

    \( \newcommand{\Argument}{\mathrm{Arg}}\) \( \newcommand{\norm}[1]{\| #1 \|}\)

    \( \newcommand{\inner}[2]{\langle #1, #2 \rangle}\)

    \( \newcommand{\Span}{\mathrm{span}}\)

    \( \newcommand{\id}{\mathrm{id}}\)

    \( \newcommand{\Span}{\mathrm{span}}\)

    \( \newcommand{\kernel}{\mathrm{null}\,}\)

    \( \newcommand{\range}{\mathrm{range}\,}\)

    \( \newcommand{\RealPart}{\mathrm{Re}}\)

    \( \newcommand{\ImaginaryPart}{\mathrm{Im}}\)

    \( \newcommand{\Argument}{\mathrm{Arg}}\)

    \( \newcommand{\norm}[1]{\| #1 \|}\)

    \( \newcommand{\inner}[2]{\langle #1, #2 \rangle}\)

    \( \newcommand{\Span}{\mathrm{span}}\) \( \newcommand{\AA}{\unicode[.8,0]{x212B}}\)

    \( \newcommand{\vectorA}[1]{\vec{#1}}      % arrow\)

    \( \newcommand{\vectorAt}[1]{\vec{\text{#1}}}      % arrow\)

    \( \newcommand{\vectorB}[1]{\overset { \scriptstyle \rightharpoonup} {\mathbf{#1}} } \)

    \( \newcommand{\vectorC}[1]{\textbf{#1}} \)

    \( \newcommand{\vectorD}[1]{\overrightarrow{#1}} \)

    \( \newcommand{\vectorDt}[1]{\overrightarrow{\text{#1}}} \)

    \( \newcommand{\vectE}[1]{\overset{-\!-\!\rightharpoonup}{\vphantom{a}\smash{\mathbf {#1}}}} \)

    \( \newcommand{\vecs}[1]{\overset { \scriptstyle \rightharpoonup} {\mathbf{#1}} } \)

    \( \newcommand{\vecd}[1]{\overset{-\!-\!\rightharpoonup}{\vphantom{a}\smash {#1}}} \)

    \(\newcommand{\avec}{\mathbf a}\) \(\newcommand{\bvec}{\mathbf b}\) \(\newcommand{\cvec}{\mathbf c}\) \(\newcommand{\dvec}{\mathbf d}\) \(\newcommand{\dtil}{\widetilde{\mathbf d}}\) \(\newcommand{\evec}{\mathbf e}\) \(\newcommand{\fvec}{\mathbf f}\) \(\newcommand{\nvec}{\mathbf n}\) \(\newcommand{\pvec}{\mathbf p}\) \(\newcommand{\qvec}{\mathbf q}\) \(\newcommand{\svec}{\mathbf s}\) \(\newcommand{\tvec}{\mathbf t}\) \(\newcommand{\uvec}{\mathbf u}\) \(\newcommand{\vvec}{\mathbf v}\) \(\newcommand{\wvec}{\mathbf w}\) \(\newcommand{\xvec}{\mathbf x}\) \(\newcommand{\yvec}{\mathbf y}\) \(\newcommand{\zvec}{\mathbf z}\) \(\newcommand{\rvec}{\mathbf r}\) \(\newcommand{\mvec}{\mathbf m}\) \(\newcommand{\zerovec}{\mathbf 0}\) \(\newcommand{\onevec}{\mathbf 1}\) \(\newcommand{\real}{\mathbb R}\) \(\newcommand{\twovec}[2]{\left[\begin{array}{r}#1 \\ #2 \end{array}\right]}\) \(\newcommand{\ctwovec}[2]{\left[\begin{array}{c}#1 \\ #2 \end{array}\right]}\) \(\newcommand{\threevec}[3]{\left[\begin{array}{r}#1 \\ #2 \\ #3 \end{array}\right]}\) \(\newcommand{\cthreevec}[3]{\left[\begin{array}{c}#1 \\ #2 \\ #3 \end{array}\right]}\) \(\newcommand{\fourvec}[4]{\left[\begin{array}{r}#1 \\ #2 \\ #3 \\ #4 \end{array}\right]}\) \(\newcommand{\cfourvec}[4]{\left[\begin{array}{c}#1 \\ #2 \\ #3 \\ #4 \end{array}\right]}\) \(\newcommand{\fivevec}[5]{\left[\begin{array}{r}#1 \\ #2 \\ #3 \\ #4 \\ #5 \\ \end{array}\right]}\) \(\newcommand{\cfivevec}[5]{\left[\begin{array}{c}#1 \\ #2 \\ #3 \\ #4 \\ #5 \\ \end{array}\right]}\) \(\newcommand{\mattwo}[4]{\left[\begin{array}{rr}#1 \amp #2 \\ #3 \amp #4 \\ \end{array}\right]}\) \(\newcommand{\laspan}[1]{\text{Span}\{#1\}}\) \(\newcommand{\bcal}{\cal B}\) \(\newcommand{\ccal}{\cal C}\) \(\newcommand{\scal}{\cal S}\) \(\newcommand{\wcal}{\cal W}\) \(\newcommand{\ecal}{\cal E}\) \(\newcommand{\coords}[2]{\left\{#1\right\}_{#2}}\) \(\newcommand{\gray}[1]{\color{gray}{#1}}\) \(\newcommand{\lgray}[1]{\color{lightgray}{#1}}\) \(\newcommand{\rank}{\operatorname{rank}}\) \(\newcommand{\row}{\text{Row}}\) \(\newcommand{\col}{\text{Col}}\) \(\renewcommand{\row}{\text{Row}}\) \(\newcommand{\nul}{\text{Nul}}\) \(\newcommand{\var}{\text{Var}}\) \(\newcommand{\corr}{\text{corr}}\) \(\newcommand{\len}[1]{\left|#1\right|}\) \(\newcommand{\bbar}{\overline{\bvec}}\) \(\newcommand{\bhat}{\widehat{\bvec}}\) \(\newcommand{\bperp}{\bvec^\perp}\) \(\newcommand{\xhat}{\widehat{\xvec}}\) \(\newcommand{\vhat}{\widehat{\vvec}}\) \(\newcommand{\uhat}{\widehat{\uvec}}\) \(\newcommand{\what}{\widehat{\wvec}}\) \(\newcommand{\Sighat}{\widehat{\Sigma}}\) \(\newcommand{\lt}{<}\) \(\newcommand{\gt}{>}\) \(\newcommand{\amp}{&}\) \(\definecolor{fillinmathshade}{gray}{0.9}\)

    • 2.0: Introduction
      This page discusses Chuck Hull's pioneering patent for stereolithography, which initiated modern additive manufacturing essential for prototyping across sectors. It explores various technologies, including polymer, metal, and ceramic processes, as well as the supplementary technologies integral to turning initial fabrication into completed parts.
    • 2.1: Processes and Process Organization
      This page discusses the ASTM F42 committee's 2012 classification of additive manufacturing (AM) technologies into seven categories, highlighting the need for an updated classification due to the fast evolution of AM technology.
    • 2.2: Vat-based Processes
      This page discusses vat-based additive manufacturing processes, specifically Stereolithography (SLA), Digital Light Projection (DLP), and Liquid Crystal Display (LCD) technologies. SLA uses UV lasers to cure resins, while DLP and LCD use projectors, differing in energy sources. Each method necessitates careful part removal and support structures, sharing common material feedstocks that must match specific light wavelengths for effective results.
    • 2.3: Powder Bed Processes
      This page provides an overview of various additive manufacturing systems, particularly focusing on different technologies such as Powder Bed Electron Beam, Laser Metal Fusion, SLS Polymer, and Binder Jet. It elaborates on their components and operational processes, including recoating methods and energy sources, with a specific emphasis on the Binder Jet's versatility.
    • 2.4: Liquid-Addition Processes
      This page discusses additive manufacturing processes including material jetting, slurry-based systems, and direct ink writing. Material jetting applies ink-like materials layer by layer, cured with UV light. Slurry-based systems speed up housing construction using a gantry system to deposit cement. Direct ink writing, also known as aerosol jetting, creates functional electronics by spraying conductive inks, requiring complex machinery for precision.
    • 2.5: Molten Material-Addition Processes
      This page details various additive manufacturing (AM) technologies, including Electron Beam Melting, Direct Energy Deposition, and polymer extrusion methods. Key features include process architecture, advantages such as reduced waste and faster processing, and material compatibility. Additionally, a cost-effective method for retrofitting cutting machines with a polymer deposition head is discussed, utilizing injection molding pellets for large components and achieving high deposition rates.
    • 2.6: Solid Material-Addition Processes
      This page describes two additive manufacturing methods: sheet lamination and cold spray technology. Sheet lamination, particularly ultrasonic consolidation, uses ultrasonic vibrations to fuse metallic foils, enabling the integration of temperature-sensitive components and dissimilar metals. Cold spray technology builds structures through high-velocity impaction of metal powders, necessitating precise tuning to avoid defects.
    • 2.7: Supporting Processes
      This page covers post-processing requirements for additive manufacturing technologies, focusing on essential steps such as powder and support removal, curing for material strength, sintering for density, and machining for precision. It emphasizes the importance of these processes to ensure high-quality AM parts, noting that variations exist depending on the specific AM technology employed.
    • 2.8: Summary
      This page discusses Additive Manufacturing (AM) technologies, highlighting various types like vat-based, powder, and molten material processes, each with specific advantages and requirements. It emphasizes the need for specialized expertise and equipment, as well as distinct procedural steps such as recoating, curing, polishing, and sintering associated with different AM methods.
    • 2.9: Review Questions
      This page covers essential questions about Additive Manufacturing (AM), including its categories, layer formation methods, feedstocks, and technologies like SLA, DLP, and LCD. It highlights curing techniques, UV wavelength compatibility, comparisons to other processes such as injection molding, and applications in home building and circuit boards.
    • 2.10: Discussion Questions
      This page discusses various additive manufacturing (AM) processes, including energy sources, technology categorization, hobbyist suitability, and the concept of "green parts." It compares binder jet technology with SLA and EBM, examines slurry-based processes for home fabrication, highlights the limitations of certain technologies, and reviews the blown powder DED application for repairs, as well as cold spray and UV curing processes in varying contexts.
    • 2.11: Case Questions
      This page discusses tasks and questions aimed at learning about additive manufacturing (AM) technologies through case studies and videos. It involves researching three AM technologies, analyzing process maps, and addressing large file size challenges. The content encourages assessing pros and cons, exploring applications, and considering future implications in AM, promoting critical thinking and knowledge application in the field.
    • 2.12: Key Terms
      This page categorizes additive manufacturing processes into sections: Vat-based (LCD, DLP, SLA), Powder Bed (sintering, de-powdering), Liquid-Addition (Direct Ink Writing), Molten Material-Addition (polymers, metals), and Solid Material-Addition (Sheet Lamination). Additional supporting processes like post-processing and build cake are also noted.


    This page titled 2: Core AM Technologies and Supporting Processes is shared under a CC BY-NC-SA 4.0 license and was authored, remixed, and/or curated by OpenStax via source content that was edited to the style and standards of the LibreTexts platform.

    • Was this article helpful?