Table of Contents
Preface vii
1 Introduction 1
1.1 A disruptive technology, additive manufacturing 1
1.2 Advantages of AM over traditional manufacturing 2
1.2.1 Greater design ability 3
1.2.2 No tooling 3
1.2.3 On-demand manufacturing 4
1.2.4 Rapid prototyping 4
1.2.5 Customization 4
1.2.6 Minimal material waste 4
1.2.7 Low cost for small number of parts 4
1.3 Classification of AM technologies 5
1.3.1 Vat polymerization 5
1.3.1.1 Stereolithography 7
1.3.1.2 Digital light processing 7
1.3.1.3 Continuous liquid interface production 7
1.3.1.4 Volumetric Vat manufacturing 8
1.3.2 Material jetting 9
1.3.3 Binder jetting 10
1.3.4 Material extrusion 11
1.3.4.1 Fused filament fabrication 11
1.3.4.2 Paste extrusion 12
1.3.5 Powder bed fusion 14
1.3.6 Directed energy deposition 15
1.3.7 Sheet lamination 16
1.4 Timeline/history of AM 19
2 Additive manufacturing of polymers 22
2.1 Classification of polymers 22
2.1.1 Thermoplastics 23
2.12 Thermosets 23
2.1.3 Elastomers 23
2.2 Selection of polymers for AM 24
2.3 AM of thermoplastic polymers 25
2.4 AM of thermosets 27
2.4.1 AM of photosensitive thermosets 27
2.4.2 AM of heat-sensitive thermosets 29
2.5 AM of elastomers 29
3 Additive manufacturing of polymer composites 31
3.1 Additive manufacturing of powder-doped polymer composites 31
3.2 Additive manufacturing of short fiber-doped composites 34
3.2.1 Short fiber reinforced thermoplastic composites 35
3.2.2 Short fiber reinforced thermoset composites 35
3.3 Prediction of mechanical properties of short fiber reinforced composites 38
3.4 Alignment of short fibers within additively manufactured composites 40
3.5 Additive manufacturing of continuous fiber reinforced composites 41
3.6 Mechanical performance comparison of additively manufactured polymer composites 45
4 Additive manufacturing of metals 47
4.1 Feedstock material fabrication for powder bed fusion 48
4.2 Feedstock materials used in metal AM 51
4.2.1 Titanium and titanium alloys 53
4.2.2 Aluminum alloys 53
4.2.3 Other metals 54
4.3 Design considerations in metal AM 54
4.3.1 Void formation 54
4.3.2 Residual thermal stresses 55
4.3.3 Surface roughness 55
4.3.4 Postprocessing 55
4.3.4.1 Stress relief 56
4.3.4.2 Heat treatment 56
4.3.4.3 Hot isostatic pressing 56
4.3.4.4 Machining and surface treatments 56
4.4 Mechanical properties of additively manufactured metals 57
5 Additive manufacturing of ceramics 61
5.1 Powder-based ceramic additive manufacturing 62
5.1.1 Binder jetting of ceramics 63
5.1.2 Powder bed fusion of ceramics 64
5.2 Slurry-based ceramic additive manufacturing 66
5.2.1 Vat polymerization of ceramics 66
5.2.2 Direct writing of ceramics 67
5.3 Bulk solid-based technologies 69
5.3.1 Sheet lamination 70
5.3.2 Fused filament fabrication 71
5.4 Additive manufacturing of polymer-derived ceramics 73
5.5 Mechanical properties of AM ceramics 74
6 Bioprinting 78
6.1 Bioprinting methods 78
6.2 Bioinktypes used in bioprinting 81
6.3 Bioprinting applications 82
6.3.1 Bioprinting of blood vessels 84
6.3.2 Skin bioprinting 85
6.3.3 Cartilage printing 85
6.3.4 Cardiac tissue bioprinting 87
6.3.5 Kidney tissue bioprinting 88
6.4 Challenges and limitations of bioprinting functional organs 88
6.5 Bioprinting in cancer research 89
7 Topology optimization 92
7.1 Topology optimization for additive manufacturing 93
7.2 Topology optimization methods 96
7.3 Solution of topology optimization problem using ANSYS finite element software 99
8 Advanced concepts in additive manufacturing 101
8.1 Hybrid additive manufacturing 101
8.1.1 Additive/subtractive hybrid manufacturing 101
8.1.2 Additive/additive hybrid manufacturing 102
8.1.3 Hybrid additive manufacturing/scaffolding technologies 104
8.2 Additive manufacturing of thermoelectric materials 106
8.3 Four-dimensional printing with smart materials 113
8.3.1 Four-dimensional printing materials 114
8.3.1.1 Four-dimensional-printed hydrogels 114
8.3.1.2 Shape-memory polymers 115
8.3.1.3 Elastomer actuators 117
8.3.2 Applications of 4D-printed structures 117
References 121
Index 135
