According to the standard classification of manufacturing technologies (DIN 8580), into which main group does Additive Manufacturing (AM) of metals primarily fall?
Manufacturing Processes according to DIN 8580:
Primary shaping (Urformen)
How many subgroups are defined under Category 1 (Primary shaping / Urformen) in DIN 8580, and which specific international standard covers the definitions and subgroups for Additive Manufacturing?
9
1.9: Primary shaping through Additive Manufacturing
DIN EN ISO/ ASTM 52900 covers the definitions and subgroups for Additve Manufacturing
What are the 7 core categories of Additive Manufacturing established under subgroup 1.9 according to DIN EN ISO/ASTM 52900?
Binder Jetting (BJT)
Directed Energy Deposition (DED)
Material Extrusion (MEX)
Powder Bed Fusion (PBF)
Material Jetting (MJ)
Sheet Lamination (SHL)
Vat Photopolymerisation (VPP)
Name the three principles of shaping based on material modification mechanisms, define how the shape is acquired for each:
Subractive Shaping:
Shape acquired by selective removal of material.
Formative shaping:
Shape acquired by the application of pressure to a raw material body.
Additive shaping:
Shape acquired by successive addition of material (layer/ units).
What are the three application levels (or application mechanisms) of Additive Manufacturing according to their industrial target use?
Rapid Prototyping:
Fast fabrication of simple, informative models to verify design properties early (parts generally cannot be used for the final application).
Rapid Manufacturing:
The direct production of functional end-use components possessing full end-product properties.
Rapid Tooling:
The production of molds and mold inserts using additive manufacturing technologies.
General advantages of Additive Manufacturing (6):
Accelerated time-to-market
Freedom in design
mass customization
supply chain consolidation
Sustainable low and mid volume production
Weight reduction and minimal waste
Sketch the cost curves comparing Additive Manufacturing and Conventional manufacturing across the three diagrams.
AM's cost advantages:
production of complex, individualized and small components,
small series production
What are the three main phases of the AM Process Flow, and what key tasks are associated with each phase?
Pre-Processing:
Data processing (CAD, CAM).
Preparing auxiliary/support structures.
Arranging parts in the build space.
Generating layer data (slicing).
In-processing:
Layer-on-layer build process.
System-level operations (e.g., part loading and unloading).
Post-Processing:
Removing powder residues and removing supports.
Steps required to obtain functional characteristics (e.g., surface finishing via subtractive methods).
Define Directed Energy Deposition (DED):
Additive manufacturing process in which a focused energy source is used to fuse materials by melting as they are being deposited
Which materials and feedstock (Ausgangsmaterial) forms are used in Directed Energy Deposition (DED), and what is the exact state of fusion during the process?
Type of Material: Metallic
Feedstock (Ausgangsmaterial): Wire, Powder
State of fusion: Melted state
State the basic AM principle, the material distribution mechanism, and the source of energy for Directed Energy Deposition (DED).
Directed Energy Deposition (DED):
basic AM principle: Selective deposition of material onto a substrate
Material distribution: Deposition nozzle
Source of Energy: Laser, Electron Beam, Arc, Plasma
Which materials and feedstock (Ausgangsmaterial) forms are used in Powder Bed Fusion (PBF), and what is the exact state of fusion during the process?
Powder Bed Fusion
Material: Metallic
feedstock: Powder
state of fusion: melted state
State the basic AM principle, the material distribution mechanism, and the source of energy for Powder Bed Fusion (PBF).
AM principle: selective fusion of material in Powder Bed
material distribution mechanism: Powder Bed
Source of energy: Electron Beam, Laser
Define Powder Bed Fusion (PBF)
Powder Bed Fusion (PBF):
AM process in which thermal energy (caused by radiation) selectively fuses regions of a powder bed.
Define Materialextrusion (MEX)
Materialextrusion (MEX):
AM process in which material is selectively dispensed through a nozzle (Düse) or orifice (Öffnung).
Which materials and feedstock (Ausgangsmaterial) forms are used in Materialextrusion (MEX), and what is the exact state of fusion during the process?
type of material: metallic + composite
feedstock (Ausgangsmaterial): filament
state of fusion: thermal reaction bonding
For Material Extrusion (MEX) of metals, state the basic AM principle, the material distribution mechanism, the intermediate result produced by AM, and the secondary process required to consolidate it into a final part.
Material Extrusion (MEX):
basic AM principle: Extrusion of melted material
material distribution: deposition nozzle
result produced by AM:
Greenbody: composite material parts joint by polymeradhesion
Consolidation by secondary process: Furnace sintering
Define Binderr Jetting (BJT)
Binder Jetting (BJT):
AM process in which a liquid bonding agent is selectively deposited to join powder materials.
Which materials and feedstock (Ausgangsmaterial) forms are used in Binder Jetting (BJT), and what is the exact state of fusion during the process?
materials: metallic + composite
feedstock (Ausgangsmaterial): powder bed + liquid
state of fusion: thermal + composite reaction bending
For Binder Jetting (BJT) of metals, state the basic AM principle, the material distribution mechanism, the intermediate result produced by AM, and the secondary process required to consolidate it into a final part.
basic AM principle: solvent reactive curing (Lösungsmittelbasierte reaktive Aushärtung)
material distribution: powder bed + print head
produced by AM:
Greenbody: composite material parts joint by polymer adhesion
Consolidation by secondary process: Furnace sintering with/ without infiltration
Based on the cumulative total number of sold industrial AM systems, which single country represents the biggest market for AM?
USA
Israel
Europe
Which specific industrial sector represents the largest market share for Additive Manufacturing applications?
Medical/ Dental
Automotive/ Aerospace
What are the top two applications for Additive Manufacturing by market share?
Functional Prototypes
End-Use parts
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