Future Challenges Complexity – more materials, greater integration, personalisation, increased use of biologics Maintaining or reducing costs – automation, disruptive manufacturing approaches Building new business models – retaining value in Europe New products and services - recognising consumer demands before they do

Advanced Manufacturing Processes Customisation Composite manufacture Manufacturing processes for renewable raw materials, biomaterials and cell based products Joining technologies for advanced and multi-materials Delivery of new functionalities through (mass production) surface manufacturing processes Manufacturing of flexible structures Product life cycle management for advanced materials

What is Additive Manufacturing? (3D Printing) The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies

Rapid prototyping, noun – additive manufacturing of a design, often iterative, for form, fit or functional testing or combination thereof.

Vat Photopolymerization Types of Aditive Manufacturing Vat Photopolymerization An additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerization. Stereolithography Envisiontec Micro-SLA …

Material Jetting An additive manufacturing process in which droplets of build material are selectively deposited Wax or Photopolymers Multiple nozzles Single nozzles …

Binder Jetting An additive manufacturing process in which a liquid bonding agent is selectively deposited to join powder materials. Zcorp Voxeljet ProMetal/ExOne …

Material Extrusion An additive manufacturing process in which material is selectively dispensed through a nozzle or orifice From microns to meters Stratasys FDM machines Office friendly DIY community Best selling platform …

Powder Bed Fusion An additive manufacturing process in which thermal energy selectively fuses regions of a powder bed SLS, SLM, DMLS, EBM, etc. Polymers, metals & ceramics

Sheet Lamination An additive manufacturing process in which sheets of material are bonded to form an object. Paper (LOM) Using glue Plastic Using glue or heat Metal Using welding or bolts Ultrasonic AM…

Directed Energy Deposition An additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited Wire & Powder Materials Lasers & Electron Beams Great for feature addition & repair

Medical imaging

Dentistry Paleontology

Architecture and Design Morongo Casino, Palm Springs, Model

Entertainment Modeling

Automotive

Advanced Composite Process Pultrusion

Advance Joining Process Friction welding -Friction heat caused by the motion of one surface against another enables plastic deformation and atomic diffusion at the interface -Used by the automotive industry for decades in the manufacture of a range of components -The weld is formed across the entire cross-sectional area of the interface in a single shot process

Direct or continuous drive Rotary Friction Welding Linear Friction Welding Friction stir welding Direct or continuous drive Pre-determined time of motion determined by the size and type of material

Linear friction welding ±1-3mm Frequency 25-125Hz Maximum axial force 150kN

Friction stir welding

Bottom Up technique uses chemical and physical interactions Advanvced Functional Material Process example nanomaterials Top Down technique uses large machines to make the nanostructures from larger materials Example: Photolithography to make Computer Processor Chips Bottom Up technique uses chemical and physical interactions to make nanostructures without guidance Example: Catalyst to make Carbon Nanotubes

Smart Materials are manufactured goods that react to some outside forces. Crystals can expand and contract with electricity, metals can retain a shape memory, liquids can move with magnetic fields, and surface cracks can heal themselves.

Processing of biomaterials