Slides accompanying 2.008x* video module on Additive Manufacturing, Prof. John Hart, MIT, 2016. *Fundamentals of Manufacturing Processes on edX: https://www.edx.org/course/fundamentals-manufacturing-processes-mitx-2-008x

1. 2.008x
Additive Manufacturing
MIT 2.008x
Prof. John Hart

2. 2.008x
E. Sachs, M. Cima, et al. MIT ~1990.

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Photo taken in Fall 2013 at MIT IDC

5. 2.008x
Earlier AM parts (arguably not the earliest)
Photopolymerization
Kodama, Rev Sci Instr. 1981
Sintering of metal/ceramic powder
Housholder, 1979 (Patent)
Image: http://nsfam.mae.ufl.edu/Slides/Beaman.pdf

6. 2.008x
Additive Manufacturing (AM) refers to a process by
which digital 3D design data is used to build up a
component in layers by depositing material.
The term ‘3D printing’ is increasingly used as a
synonym for AM. However, the latter is more accurate in
that it describes a professional production technique
which is clearly distinguished from conventional
methods of material removal.
From the International Committee F42 for Additive Manufacturing Technologies, ASTM.
and http://www.eos.info/additive_manufacturing/for_technology_interested

7. 2.008x
Material removal (“top-down”)
Material addition
“bottom-up”
CNC machining image © 2016 Dungarvan Precision Engineering
http://dpe.ie/cnc-milling/

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Why is AM such a big
deal now?
§ Wide availability of CAD/CAM
software.
§ Improved automation and
component technologies.
§ A growing library of ‘printable’
materials.
§ Major industry and government
investment.
§ Freedom to operate enabled by
patent expirations.
§ Momentum, confidence, and
creative vision.

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Agenda: Additive
Manufacturing
§ What and why?
§ Overview of AM processes
§ Extrusion AM (FFF/FDM)
§ Photopolymerization (SLA)
§ Powder bed fusion
(SLS/SLM)
§ Emerging AM technologies
§ Conclusion

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Additive Manufacturing:
2. What can AM do and
why is it so important?

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The AM industry today
Wohlers report 2016
Machines
Services
2015: $5.2B AM machines and services
2015 growth = 26%
27-year CAGR = 26%
Worldwide mfg is ~$15 trillion (16% of
the world economy)
àà AM = 0.03%.

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The AM industry today
“How do you use the parts made on your
industrial AM machines?”
Ti64 hip implant cups
(Arcam)
Orthodontic aligners
(Align Tech)
Wohlers report 2016

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Aston
Martin DB7:
Skyfall
Custom airway stent: U. Michigan
Shoe cleats: NIKE
Tooling: Linear Mold,
Triform
Airbus
GE leap fuel nozzle
The diverse industrial uses of AM
Modular products:
Google Ara

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Why Additive Mfg?
§ Fast prototyping
§ Complex geometries
§ Mutiple materials; new materials
§ Enhanced performance
§ Low-volume (personalized?)
manufacturing
§ etc..

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Gibson, Rosen, and Stucker. Additive Manufacturing Technologies
Could this be machined?

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What additive
manufacturing
processes have you
used?
What was your
experience?

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How good (or bad) is additive manufacturing?
(it depends on the process, machine, settings, and post-processing)
Rate LOW 0.01-1 kg/hr
(getting better!)
Quality LOW ~0.1 mm resolution
(rate-quality tradeoff)
Cost HIGH $0.1-10 per gram!
(highly dependent on
material and process)
Flexibility AMAZING (if you know what to do)

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Manufacturing:
value at scale

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AM lets us redefine
value and scale
àà How do we get
there?
Conner et al. Additive Manufacturing, 2014

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AM lets us redefine
value and scale
Conner et al. Additive Manufacturing, 2014

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R. D’Aveni, Harvard Business Review, May 2015

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Additive Manufacturing:
3. Overview of AM
processes

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Fused filament
fabrication (FFF/FDM)
Atlas V
rocket
component
(Stratasys)
Stereolithography
(SLA)
Formlabs /
www.deschaud.fr
Materialise
http://www.c3plasticdes
ign.co.uk/stereolithogra
phy-process.html
Selective laser
sintering / melting (SLS/SLM)
EOS

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Material and Binder Jetting
Laminated Object
Manufacturing (LOM)
Directed Energy Deposition
Stratasys/Objet
mCorFabrisonic
Sciaky
Optomec
Objet
Voxeljet
https://en.wikipedia.org/wiki/Laminat
ed_object_manufacturing

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The 7 AM methods (from ASTM F42)
§ Vat photopolymerization (àà SLA): material is
cured by light-activated polymerization.
§ Material jetting (à Objet): droplets of build material
are jetted to form an object.
§ Binder jetting (à 3DP): liquid bonding agent is jetted
to join powder materials.
§ Material extrusion (àà FFF/FDM): material is
selectively dispensed through a nozzle and solidifies.
§ Sheet lamination (à LOM): sheets are bonded to
form an object.
§ Powder bed fusion (àà SLS/SLM): energy (typically
a laser or electron beam) is used to selectively fuse
regions of a powder bed.
§ Directed energy deposition (à LENS): focused
thermal energy is used to fuse materials by melting
as deposition occurs.
LowenergyHighenergy

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We must master all the steps
Gibson, Rosen and Stucker, Additive Manufacturing Technologies

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28. 2.008x
Additive Manufacturing:
4. Extrusion processes
(i.e., Fused Filament Fabrication, FFF
Fused Deposition Modeling, FDM)

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Nozzle
Build platform

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iPhone dock
Matt Haughey (CC BY-NC-SA 2.0)
Aircraft duct
Image © WTWH Media LLC
Ultimaker 2
~US$2,500: 10 x 9 x 8”
Stratasys Fortus
~US$150,000: 16 x 14 x 16”
~US$400,000: 36 x 24 x 36”
Image©UltimakerB.V.
Image©StratasysLtd.

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from Solid Concepts: excerpt of https://youtu.be/WHO6G67GJbM
Fused Deposition Modeling (FDM)

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Stratasys FDM
materials

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Build plate
Support
Raft (base)
Part
FDM part nomenclature

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Discretization and toolpath effects
Diagrams from Gibson, Rosen and Stucker, Additive Manufacturing Technologies
Accuracy Strength

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Polymer extrusion in FDM
Thermoplastic
à amorphous polymer network,
linear chain architecture
Comparison to injection into a mold
Tf = forming temp.
The chains align then slip during flow
Heated bed
ABS ~80C
Extruder
ABS ~260C
Groover, Fundamentals of Modern Manufacturing
Osswald et al., International Plastics Handbook
Malloy, Plastic Part Design Injection Molding

37. 2.008x
A dual extruder

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Extrusion force vs temperature
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
0 2 4 6 8 10 12 14 16
Extruder(Force((N)
Feed(Rate((mm/s)
200+C
230+C
260+C
59+N
à Force increases with feed rate
à Force is greater at lower temperature
à Force saturates at ~60 N
Extruder
Load+cell
Heater
assembly
Jamison Go

39. 2.008x
Shear failure of the filament
Drive knurls
(normal operation)
Material shear
(extrusion failure)
1 mm
Drive&wheel
Filament&
shear&area
Material&
under&drive&
wheel&teeth
Feed Direction

40. 2.008x
Geometry of the FDM nozzle
𝑰𝑰
𝑰𝑰𝑰𝑰
𝑰𝑰𝑰𝑰𝑰𝑰
𝑙𝑙#
𝑙𝑙$
𝑑𝑑#
𝑑𝑑$
𝛽𝛽
Heater block
Extrusion nozzle
I
II, III
Zone I: heating
Zone II: transition
Zone III: area reduction (dominates pressure drop)

41. 2.008x
Extrusion rate is limited by heat transfer
à Feed rates found to cause extrusion failure correspond with inadequate
filament core temperatures
3 mm/s 9 mm/s1 mm/s
Temperature(C)
1 mm/s
3 mm/s
9 mm/s

42. 2.008x
ABS blended with chopped carbon fiber
~5 mm bead size
Big area additive manufacturing (BAAM!)

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Stratasys Mojo = 65 min
BAAM ~30 min

48. 2.008x
FDM: other topics
§ Support criteria and
removal
§ Mechanics (= anisotropy)
§ Surface finishing
Smoothing FDM Images © Shapeways, Inc.
Ahn et al., “Anisotropic Material
Properties of Fused Deposition
Modeling (FDM) ABS,” 2002.
FDM figurine Image © 3D Genius

49. 2.008x
Additive Manufacturing:
5. Photopolymerization
(Stereolithography, SLA)

50. 2.008x
Materialise NV (Belgium): excerpt from https://www.youtube.com/watch?v=98xG86GKj7A
à Material is cured by light-activated polymerization.
Stereolithography (SLA)

51. 2.008x
Image © CustomPartNet

52. 2.008x
Prototype parts
Applications of SLA
Presentation models
Personalized
products
Phidgets
FOPAT Production Inc.
Tri-Tech 3D
Innovated Solutions
© Moises Fernandez Acosta
Short-run tooling
Invisalign

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SLA vs FDM: layer thickness
Form1 (SLA) Stratasys Mojo (FDM)

56. 2.008x
SLA vs FDM: toolpath
Form1 (SLA) Stratasys Mojo (FDM)

57. 2.008x
How the flash of light works:
photopolymerization (a.k.a photocuring)
àà Crosslinked network
(thermoset)
Yagci Polymer Research Group, Istanbul Technical University
Image © Formlabs
PI RŸ
hv
M+RŸ P1Ÿ
k1
PnŸ+M Pn+1Ÿ
kp
PnŸ+PmŸ Mn+m /Mn+Mm
ktc
initiation
propagation
termination by combination
A photoinitiator (PI) turns into a primary radical (RŸ) through photon excitation. A chain
grows by the addition of monomer units (M) to a polymeric radical of length n (Pn), finally
forming stable polymer units of length n (Mn).

58. 2.008x
1. The laser beam scans the surface of the resin
2. Each laser pass cures a parabolic
cross-section of the resin
3. Resin properties determine the relationship
between light exposure and cure depth
(1mil=0.001”
=25.4microns)
From an example SLA resin
Gibson, Rosen and Stucker, Additive Manufacturing Technologies
y
x
v
(xstart, ystart)
Point i (xi yi)
(xend, yend)
yi
position x
Intensity [W/m2]Amplitude of electric
field [V/m]
Figure 1 (b) from "Epoxy and Acrylate Stereolithography
Resins: In-Situ Measurements of Cure Shrinkage and
Stress Relaxation" by Guess, et al.

59. 2.008x
Layers
The complete scan pattern
A ‘Star-weave’ pattern is
used to raster the surface
Top view
Side view
à This allows the resin to shrink
locally while curing (it happens)
while minimizing overall part
shrinkage and residual stress.
hs
0.01 inch
Hatch
Border
Side view
Gibson, Rosen and Stucker, Additive Manufacturing Technologies

60. 2.008x
?

61. 2.008x
Inside the Form1
Formlabs
Laser
Andrew (bunnie) Huang (CC BY-SA 3.0)

62. 2.008x
3D Systems, Inc. May 2016

63. 2.008x
SLA: other topics
§ Support criteria and
removal
§ Mechanics and durability
§ Surface finishing

64. 2.008x
Additive Manufacturing:
6. Powder bed fusion
(i.e., Selective Laser Sintering, SLS
Selective Laser Melting, SLM)

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Selective Laser Melting (SLM)
Excerpt from: https://www.youtube.com/watch?v=zqWOrwBzOjU

66. 2.008x
EOS GmbH Electro Optical Systems

67. 2.008x
Applications of SLM parts
Aerospace
Medical
Manufacturing
SpaceX
EOS (Images © MachineDesign.com)
Airbus (Image © BBC)
Arcam AB
General Electric
Company
AMG Advanced Metallurgical Group

68. 2.008x
Powder fusion AM applies to many materials
Dyson
From J.P. Kruth
Image © Best Vacuum Cleaners
Reviews
Image from VintageHoover via YouTube

69. 2.008x
at Nanyang Technological University (Singapore), August 2014

70. 2.008x
Figure 1 from “Binding Mechanisms in Selective Laser Sintering and
Selective Laser Melting” by Kruth, et al. 2004
Critical process parameters
§ Laser power
§ Laser scan speed
§ Laser scan pattern
§ Particle size and packing density
§ Layer uniformity and thickness
§ Bed temperature
§ And more..

71. 2.008x
Lasers: wavelength and absorption
Figure from "Additive Manufacturing Technologies" by Gibson, et al. (2010)

72. 2.008x
What’s different for SLM? (vs. FDM, SLA)
§ Powder = can be ~anything (flexibility, bulk properties!)
à Typically ~10-100um diameter (wide size distribution)
§ Complexity of powder handling (why?)
§ Flammable
§ Inhalation risk
§ Oxidation/contamination à often need inert atmosphere for metals
§ Energy required = high
§ SLA: 0.1 W for photopolymerization (at ~1 m/s scan)
§ FDM: 1-10 W for melting the filament
§ SLM: 100-1000 W for melting the powder (at ~1-10 m/s scan)
§ Post-processing: powder removal, machining away metal
support

73. 2.008x
SLM: Mechanism Cross-section of SLM part

74. 2.008x
Before and after
Figure 5 f) from "Analysis of defect generation in Ti-6Al-4V parts made using
powder bed fusion additive manufacturing processes" by Gong, et al., Additive
Manufacturing (2014)
Advanced Powders and Coatings Inc.
15-45 um 45-106 um0-25 um
Advanced Powders and Coatings Inc.

75. 2.008x
Zone%II
(subsurface%voids)
Zone%I%(fully%
dense)
Process map: SLM of Ti64
Gong, et al, “Analysis of defect generation in Ti–6Al–4V parts
made using powder bed fusion additive manufacturing
processes,” Additive Manufacturing, 2014.
Zone I: Fully dense (few defects)
Zone II: Sub-surface porosity due to excess
heating (gas bubble generation, trapped, do not
appear on surface)
Zone III: Insufficient melting
OH: Serious surface deformation (jams recoater)
Increasing energy
density

76. 2.008x
Process map: SLM of Ti64
Gong, et al, “Analysis of defect generation in Ti–6Al–4V parts
made using powder bed fusion additive manufacturing
processes,” Additive Manufacturing, 2014.
Zone I: Fully dense (few defects)
Zone II: Sub-surface porosity due to excess
heating (gas bubble generation, trapped, do not
appear on surface)
Zone III: Insufficient melting
OH: Serious surface deformation (jams recoater)
Overheated)
Zone)III
(underheat)

77. 2.008x
Prof. JP Kruth says…
During SLM, the short interaction of powder bed and
heat source caused by the high scanning speed of
the laser beam leads to rapid heating, melting
followed by drastic shrinkage (from 50% powder
apparent density to ~100% density in one step), and
circulation of the molten metal driven by surface
tension gradients coupled with temperature
gradients.
The resulting heat transfer and fluid flow affect the size
and shape of the melt pool, the cooling rate, and the
transformation reactions in the melt pool and heat-
affected zone.
The melt pool geometry, in turn, influences the grain
growth and the resulting microstructure of the part.

78. 2.008x
Chaos in the melt pool!
à Evaporation and recoil
à Ejection of ‘sparks’ (hot droplets)
Presented by Dr. Wayne King (LLNL) at ASME AM3D 2015

79. 2.008x
Typical (general) scan patterns
Carter et al. J. Alloys and Compounds 2014.
Gibson et al. 2015

80. 2.008x
Ti frame = 1400g
Renishaw Plc; http://www.core77.com/blog/digital_fabrication/from_the_uk_the_worlds_first_3d-
printed_bike_frame_26463.asp
Success! Lots of parts in
close proximity.
Renishaw plc

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82. 2.008x
Vrancken, et al. (2012) doi:10.1016/j.jallcom.2012.07.022
Mechanical properties of SLM Ti64
à Fine microstructure = high strength
à Small defects = lower ductility than standard (wrought) material
à Highly dependent on process parameters including post-print annealing!

83. 2.008x
SLM market dynamics
From manufacturer data, 2015.
EOS M 400

84. 2.008x
Ti6Al4V hip implant cups
§ >40,000 acetabular (hip cup) implants in patients (Wohlers 2014);
approved in Europe and US.
§ Surface texture promotes osseointegration (bone attachment).
§ Arcam (EBM):
§ “now allows the ability to specify pore geometry, pore size, and density and
roughness of structures for trabecular structures and surfaces.”
§ 16 cups built simultaneously in 8 hours à then post-processing (intensive).
EOS/Arcam/Within; orthoinfo.aaos.org/topic.cfm?topic=a00377

85. 2.008x
Additive Manufacturing:
7. Emerging Process
Technologies

86. 2.008x
High speed SLA: Carbon3D ‘Continuous liquid
interphase production’ (CLIP)
Carbon3D, Inc. / Tumbleston et al. Science, 2015.
TED talk by Prof. Joe DeSimone:
https://www.ted.com/talks/joe_desimone_what_if_3d_printing_was_25x_faster?language=en
Legacy effects / carbon3D
Ford / carbon3D
Dead zone thickness ~20-30 μm

87. 2.008x
Industrial automation of AM
Additive Industries: http://additiveindustries.com/Industrial-am-systems/Metalfab1
screenshot from https://www.youtube.com/watch?v=TssX2JsL0uk

88. 2.008x
MoriHybrid AM and machining

89. 2.008x

90. 2.008x

91. 2.008xFiber composites (Markforged) Integrated electronics
(Voxel8)
Images © www.3Ders.org, Voxel8
© MarkForged, Inc.
© MarkForged, Inc.
© MarkForged, Inc.
AM of advanced materials

92. 2.008x
Additive Manufacturing:
8. Conclusion

93. 2.008x
RateCost
Quality Flexibility

94. 2.008x
Challenges to
accelerate AM
§ Design tools and data
management to fully realize the
potential of AM.
§ Process control; higher quality
at faster rate and process/part
qualification.
§ Standards.
§ Education!

95. 2.008x
(IBM report)
http://www-
935.ibm.com/services/us/gbs/thoughtlead
ership/software-defined-supply-chain/
AM will catalyze digital supply chains

96. 2.008x
References
1 Introduction
Image of GE fuel nozzle airflow diagram © 2016 General Electric
GE leap fuel nozzle image Copyright © 2016 Penton
Titanium aircraft brackets produced by conventional manufacturing and additive
manufacturing © 2016 Business Wire
Aston Martin DB5 prop from the movie "Skyfall" Photo © Voxeljet AG
X-ray of a child's airway and a 3D printed bioresorbable airway stent, Image Copyright ©
2016 Massachusetts Medical Society. All Rights Reserved.
Tooling inserts with internal cooling channels ©Linear AMS All Rights Reserved
Tooling mold for sheet metal forming, photo © Dave Pierson.
Image in Fast Company & Inc © 2016 Mansueto Ventures, LLC
Project Ara modular smartphone components, photo © Google, Inc.
Google Ara modular smartphone photo © 2016 AOL Inc. All Rights Reserved.

97. 2.008x
References
3D printed MIT dome © John Hart
Hagia Sofia, Istanbul, photo on boisestate.edu by E.L. Skip Knox
Cima, Micheal, et al. "Three-dimensional printing techniques: US 5387380 [P]."
Photo of first 3D printer at MIT © John Hart
Clear printed part: Figure 7 from "Automatic method for fabricating a three-dimensional
plastic model with photo-hardening polymer" by Kodama, Rev. Sci. Instrum. 52 (11),
November 1981, 1770-1773; © 1981 American Institute of Physics
Patent schematic: Figure 1 from "Automatic method for fabricating a three-dimensional
plastic model with photo-hardening polymer" by Kodama, Rev. Sci. Instrum. 52 (11),
November 1981, 1770-1773; © 1981 American Institute of Physics
Molding Process US Patent 4247508 schematic, figure 15. This work is in the public
domain.
Photos from slide presentation by Joseph Beaman, University of Texas at Austin.
CNC machining photo © Dungarvan Precision Engineering
FDM printing with a Solidoodle 3D printer © John Hart
Article Copyright by ASTM Int'l (All Rights Reserved).

98. 2.008x
References
2 Importance of Additive Manufacturing
Additive manufacturing analytics, Image © Wohlers Associates, Inc.
Image of GE fuel nozzle airflow diagram © 2016 General Electric
GE leap fuel nozzle image Copyright © 2016 Penton
Titanium aircraft brackets produced by conventional manufacturing and additive
manufacturing © 2016 Business Wire
Aston Martin DB5 prop from the movie "Skyfall" Photo © Voxeljet AG
X-ray of a child's airway and a 3D printed bioresorbable airway stent, Image Copyright ©
2016 Massachusetts Medical Society. All Rights Reserved.
Image of tooling with cooling channels ©Linear AMS All Rights Reserved
Photo of tooling mold for sheet metal forming © Dave Pierson.
Image in Fast Company & Inc © 2016 Mansueto Ventures, LLC
Project Ara modular smartphone components, photo © Google, Inc.
Google Ara modular smartphone photo © 2016 AOL Inc. All Rights Reserved.

99. 2.008x
References
Image of pie chart © Wohlers Associates, Inc.
Invisalign clear dental braces, image © invisalign.com 2016
Titanium hip implant, image © Arcam AB.
3D printing potato chips, video ©1996-2016 TheStreet, Inc. All Rights Reserved.
Figure 1.3 from "Additive Manufacturing Technologies (2nd Edition)" by Gibson, et al.
(2015) © Springer International Publishing AG, Part of Springer Science+Business Media
iPhone 5, photo by Justin Sullivan © Getty Images.
Volvo C30 T5 R-design hatchback, photo © Auto-Power-Girl.com 2006-2015. All Rights
Reserved.
Water desalination facility, photo © F.D.W.A. All Rights Reserved.
Froti-Lay potato chip production, photo by Peter Desilva of the New York Times. © 2016
The New York Times Company.
Lays potato chips, image © 2016 Frito-Lay North America, Inc.
DePuy hip implant, image © DePuy Synthes 2014-2016. All Rights Reserved.
Bathroom sink, photo by User: Tomwsulcer via wikimedia - CC0. This work is in the public
domain.

100. 2.008x
References
"Making sense of 3-D printing: Creating a map of additive manufacturing products and
services" Figures 2 and 6, by Conner, et al., Additive Manufacturing (2014). © Elsevier
B.V.
Photo of Harvard Business Review Cover by Bruce Peterson. Copyright © 2016 Harvard
Business School Publishing. All Rights Reserved.
3 Overview
Rocket air duct printed by FDM image copyright © 2016 Stratasys Direct, Inc. All Rights
Reserved.
Video if Solidoodle FDM printer, © John Hart
Stereolithography process, image © www.C3plasticdesign.co.uk
Large scale stereolithography, Video by Materialise NV © 2016
SLS diagram Figure 1 from Title: Binding Mechanisms in Selective Laser Sintering and
Selective Laser Melting; Authors: P. Kruth, P. Mercelis, L. Froyen, Marleen Rombouts;
Journal: SSF 2004 Proceedings; Year: August 4, 2004; Pages: 44-59. © Emerald Group
Publishing Limited
Photo of EOS selective laser sintered parts © John Hart

101. 2.008x
References
Inkjet droplet impact on a glass sheet, image Copyright © Shimadzu Corporation. All
Rights Reserved.
Objet digital material composition, image Copyright © 2016 Stratasys Direct, Inc. All
Rights Reserved.
Fabrisonic lamintated object manufacturing sample, photo © Fabrisonic 2016
Laminated object manufacturing printing head, photo Copyright © 2016
ENGINEERING.com, Inc.
Photo oF Optomec LENS metal laser deposition copyright 2016 Optomec. All Rights
Reserved
Directed energy deposition schematic, image © Oerlikon Corporation AG, Metco
Electron beam additive manufacturing of a metal bowl, photo © 2016 Sciaky Inc. All
Rights Reserved.
Schematic of the vat photopolymerization process, image © 2016 Loughborough
University. All Rights Reserved.
Schematic of the fused deposition modeling process, image © 2016 Loughborough
University. All Rights Reserved.
Material jetting combined with photopolymerization, image Copyright © 2009
CustomPartNet. All Rights Reserved.

102. 2.008x
References
Sheet lamination schematic. image © 2016 Loughborough University. All rights reserved.
Selective laser sintering schematic, image © 2016 Loughborough University. All Rights
Reserved.
Directed energy deposition schematic, image © 2016 Loughborough University. All Rights
Reserved.
CAD to part process, Figure 1.2 from "Additive Manufacturing Technologies (2nd Edition)"
by Gibson, et al. (2015). © Springer International Publishing AG, Part of Springer
Science+Business Media
FDM process diagram © John Hart
3D printed Poseidon sculpture, photo © Gilles-Alexandre Deschaud.
Selective laser melting in action, video © John Hart
Binder jetting process schematic, image Copyright © 2016 Penton
Sand mold core made by binder jetting and cast part, photo © Voxeljet AG
Soft polymer heart printed by binder jetting © John Hart
Ultrasonic additive manufacturing, image © Copyright 2016, Peerless Media, LLC. All
Rights Reserved

103. 2.008x
References
Laminated object manufacturing process schematic, image by User: Laurens van
Lieshout (LaurensvanLieshout) via Wikimedia. (CC BY-SA) 3.0
4 Extrusion Processes
FDM printing using the Solidoodle printer, video © John Hart
FDM process diagram © John Hart
Ultimaker FDM printer, image © 2016 Ultimaker B.V.
3D printed iPhone 5 dock, image by Matt Haughey (CC BY-NC-SA 2.0)
Stratasys Fortus 400mc printer, image Copyright © 2016 Stratasys Direct, Inc. All Rights
Reserved.
Aircraft air duct, image Copyright © 2016 · All Rights Reserved WTWH Media LLC
Fused deposition modeling, video Copyright © 2016 Stratasys Direct, Inc. All Rights
Reserved.
Stratasys FDM materials list, image Copyright © 2016 Stratasys Direct, Inc. All Rights
Reserved.
UP Mini time lapse video © John Hart
3D printed ship wheel, image © John Hart

104. 2.008x
References
CAD rendering of a Yo-Yo assembly © MIT
FDM filament path, Figures 6.3 and 6.5 from "Additive Manufacturing Technologies (2nd
Edition)" by Gibson, et al. (2015). © Springer International Publishing AG, Part of
Springer Science+Business Media
Amorphous polymer network, Figure 1.2 from "Plastic Part Design Injection Molding (2nd
edition)" by Malloy (1994). © Hanser Publishers (1994)
Photo of FDM printed part on a Solidoodle printer © John Hart
Injection molding machine diagram, Figure 13.21 from Title: Fundamentals of Modern
Manufacturing; Author: Mikell P. Groover; © Wiley; (2010);
Tensile stress and strain as a function of temperature for an amorphous thermoplastic,
Figure 2.26 from "International Plastics Handbook" by Osswald et al. © Hanser
Publishers (2006).
Photograph of dual nozzle extruder © John Hart
Extrusion force versus feed rate, Image by Jamison Go © MIT. All Rights Reserved.
Pinch wheel teeth and shear area CAD schematic, image by Jamison Go © MIT. All
Rights Reserved.
Picture of sheared filament, image by Jamison Go © MIT. All Rights Reserved.

105. 2.008x
References
Diagram of filament material flow, mage by Jamison Go © MIT. All Rights Reserved.
Big Area Additive Manufacturing system printing a chair, video © John Hart
Big Area Additive Manufacturing feedstock, image © John Hart
Layering in 3D printed chair with measuring tape reference, image © John Hart
Big Area Additive Manufacturing Facility, Oak Ridge National Laboratory, image © John
Hart
Willys Jeep 3D printed model, image © John Hart
Scale model of 3D printed chair, printed on the Mojo FDM printer, © John Hart
Chair printed by Big Area Additive Manufacturing, © John Hart
FDM overhang angle illustration, image © John Hart
Image © 2015 3D Genius – The Home of 3D Printing.
Fracture surface SEM image of FDM ABS specimen, figure 11 from Title: Anisotropic
Material Properties of Fused Deposition Modeling (FDM) ABS; Authors: S. H. Ahn, M.
Montero, D. Odell, S. Roundy, and P. K. Wright; Journal: Rapid Prototyping Journal;
Volume: 8; Number: 4; Year: 2002; Pages: 248-257. © Emerald Group Publishing Limited

106. 2.008x
References
SEM images showing the effect of Stratasys vapor smoothing on FDM part surfaces,
photo © 2016 Shapeways, Inc.
5 Photopolymerization
Materialise large scale SLA, video by Materialise NV © 2016
Prototype SLA enclosure, image © 2016 Phidgets
Short-run SLA tooling, image © 2016 FOPAT
Engine block printed by binder jetting, Image © Tri-Tech3D
SLA city scape, image © Copyright - Innovated Solutions
Invisalign clear braces, image © invisalign.com 2016
Stereolithography process diagram, image Copyright © 2009 CustomPartNet. All Rights
Reserved.
Materialise large scale SLA, still from video by Materialise NV © 2016
3D printed prototype hamster and hamster wheel, image © John Hart
SLA and FDM printed salt shakers, photo © John Hart

107. 2.008x
References
Photopolymerization, diagram by Dr. Yusuf Yagci of Istanbul Technical University.
Copyright 2010 All Rights Reserved.
Thermoset polymer structure, Figure 7.5d from Title: Manufacturing Engineering &
Technology (6th Edition); Authors: Serope Kalpakjian, Steven Schmid; © Prentice Hall;
(2009)
Light exposure intensity distribution, © MIT. All Rights Reserved.
Cure depth in photopolymerization, Figures 4.6 and 4.7 from "Additive Manufacturing
Technologies (2nd Edition)" by Gibson, et al. (2015). © Springer International Publishing
AG, Part of Springer Science+Business Media
Laser scanning patterns, Figures 4.10 b) and 4.12 from "Additive Manufacturing
Technologies (2nd Edition)" by Gibson, et al. (2015). © Springer International Publishing
AG, Part of Springer Science+Business Media
Time lapse of 3D printing using a Form 1, video © John Hart
Formlabs photoresin, photo © Formlabs 2016, Inc. All Rights Reserved.
Exposure at a point in SLA, © MIT. All Rights Reserved.
Cured resin cross-section, figure 1 (b) from Title: Epoxy and Acrylate Stereolithography
Resins: In-Situ Property Measurements; Authors: T. R. Guess, R. S. Chambers, T. D.
Hinnerichs; Year: January 1996; Journal: Sandia Report SAND95-2871. This work is in
the public domain.

108. 2.008x
References
SEM image and turbine blade photo, image © John Hart
Formlabs Form 1 printer specifications, article © Formlabs 2016, Inc. All Rights
Reserved.
Formlabs Form 1 teardown, photo by (bunnie) Andrew Huang is licensed under a
Creative Commons Attribution-ShareAlike 4.0 International License.
3D Systems ProX 950 specifications, article © 2014 by 3D Systems Inc. All Rights
Reserved.
6 Powder Bed Fusion
EOS tooling, video © EOS GmbH Electro Optical Systems
EOS rook made by selective laser sintering, image © EOS GmbH Electro Optical
Systems
Jet engine cross-section, image ©AMG Advanced Metallurgical Group, 2010 All Rights
Reserved.
GE LEAP fuel nozzle, image © 2016 General Electric
Low pressure turbine blade, photo © Arcam A.B.
SpaceX inconel rocket chamber, photo © Elon Musk via Twitter.

109. 2.008x
References
Airbus bracket manufactured by conventional manufacturing and 3D printing, photo
Copyright © 2016 BBC.
EOS tooling with integrated cooling channels, image Copyright © 2016 Penton
Hip implant, image Copyright ©1995-2016 by the American Academy of Orthopaedic
Surgeons.
Arcam 3D printed implant, image © Arcam AB.
Arcam skull remodeling implant, image © Arcam AB.
Polyamide, steel, titanium, composite and ceramic parts, image © Prof. Dr. Ir. Jean-Pierre
Kruth; KU Leuven university, Belgium
Dyson DC25, image Copyright © 2011-2014 Best Vacuum Cleaners Reviews
Dyson rapid prototype SLS, image from www.vintagehooveremporium.com © 2005 All
Rights Reserved.
SLM solutions 250HL printer, image © John Hart
SLS diagram figure 1 from Title: Binding Mechanisms in Selective Laser Sintering and
Selective Laser Melting; Authors: P. Kruth, P. Mercelis, L. Froyen, Marleen Rombouts;
Journal: SSF 2004 Proceedings; Year: August 4, 2004; Pages: 44-59. © Emerald Group
Publishing Limited

110. 2.008x
References
Absorptivity of various metals, Figure 5.10 from "Additive Manufacturing Technologies" by
Gibson, et al. (2010). © Springer International Publishing AG, Part of Springer
Science+Business Media
Side view of an SLM micrograph figure 15 c) from Title: Part and material properties in
selective laser melting of metals; Authors: J.-P. Kruth, M. Badrossamay, E.Yasa, J.
Deckers, L. Thijs, J. Van Humbeeck; Journal: Proceedings of the 16th International
Symposium on Electromachining; Year: 19-23 April, 2010. © Shanghai Jiaotong
University Press, Shang Hai, 2010
Epitaxial growth during selective laser sintering, Figure 2 from "Physical Aspects of
Process Control in Selective Laser Sintering of Metals" by Das, Advanced Engineering
Materials 5(10), 2003. © Shanghai Jiaotong University Press, Shang Hai
SLM processed Ti-6Al-4V powder, Figure 5 f) from "Analysis of defect generation in Ti-
6Al-4V parts made using powder bed fusion additive manufacturing processes" by Gong,
et al., Additive Manufacturing (2014). Copyright © 2016 Elsevier B.V.
SEM images of SLM processed Ti-6Al-4V powder, Figure 5 a) and f) from "Analysis of
defect generation in Ti-6Al-4V parts made using powder bed fusion additive
manufacturing processes" by Gong, et al., Additive Manufacturing (2014). Copyright ©
2016 Elsevier B.V.
SLM process window, Figure 4 from "Analysis of defect generation in Ti-6Al-4V parts
made using powder bed fusion additive manufacturing processes" by Gong, et al.,
Additive Manufacturing (2014). Copyright © 2016 Elsevier B.V.

111. 2.008x
References
SEM images of Ti-6Al-4V powder, Figure 5 d) and k) from "Analysis of defect generation
in Ti-6Al-4V parts made using powder bed fusion additive manufacturing processes" by
Gong, et al., Additive Manufacturing (2014). Copyright © 2016 Elsevier B.V.
Schematic of the laser melt pool, Figure 16 from "Analysis of defect generation in Ti-6Al-
4V parts made using powder bed fusion additive manufacturing processes" by Gong, et
al., Additive Manufacturing (2014). Copyright © 2016 Elsevier B.V.
Title crop of paper: Part and material properties in selective laser melting of metals;
Authors: J.-P. Kruth, M. Badrossamay, E.Yasa, J. Deckers, L. Thijs, J. Van Humbeeck;
Journal: Proceedings of the 16th International Symposium on Electromachining; Year: 19-
23 April, 2010. © Shanghai Jiaotong University Press, Shang Hai
Prof. J.P. Kruth, Photo Copyright © KU Leuven
Video by A.J. Hart, of Wayne King at Lawrence Livermore National Laboratory, U.S. Dept.
of Energy. This work is in the public domain.
Island scan strategy in SLM, Figure 3 from "The influence of the laser scan strategy on
grain structure and cracking behaviour in SLM powder-bed fabricated nickel superalloy"
by Carter, et al., Journal of Alloys and Compounds (2014). Copyright © 2016 Elsevier
B.V.
Scanning path for powder bed fusion, Figure 5.7 from "Additive Manufacturing
Technologies (2nd Edition)" by Gibson, et al. (2015). © Springer International Publishing
AG, Part of Springer Science+Business Media

112. 2.008x
References
Empire 3D printed bicycle frame, Photo © 2001-2016 Renishaw plc. All Rights Reserved.
Picture of Tim Simpson, Photo © Tim Simpson.
Mechanical test of SLM printed specimens before and after heat treating, Figure 8 from
"Heat treatment of Ti6Al4V produced by Selective Laser Melting: Microstructure and
Mechanical properties" by Vrancken, et al., Journal of Alloys and Compounds (2012).
Copyright © 2016 Elsevier B.V. or its licensors or contributors
EOS M400 printer, photo © EOS GmbH Electro Optical Systems
Machine cost versus build volume, image © John Hart
Titanium hip implant, image © Arcam AB.
7 Emerging Technologies
Continuous liquid interface printing of an Eifel Tower model, video © Carbon
Continuous Liquid Interface Production, Figure 1 (A) and (C 3) from "Continuous liquid
interface production of 3D objects" by Tumbleston, et al., Science Magazine 347(6228),
March 20, 2015. © 2016 EBSCO Industries, Inc. All Rights Reserved.
Rapid prototype of oil fill tube, Photo © Carbon
3D printed "Iron Man" articles Image Copyright © 2016. 3DR Holdings, LLC, All Rights
Reserved.

113. 2.008x
References
Rendering of Additive Industries MetalFAB1 copyright © Additive Industries
Still of Additive Industries MetalFAB1 copyright © Additive Industries
DMG Mori Lasertec 65 additive and subtractive manufacturing machine, Video Copyright
© 2016 DMG MORI All Rights Reserved.
DMG Mori Research Facility, image © John Hart
Turbine blades manufactured by DMG MORI © John Hart
Mark One composite 3D printer, photo Copyright ©2016 - 3D Printing Blog -
FDM printed bike crank with continuous carbon fiber reinforcement, image ©2016
Markforged, Inc.
Kevlar reinforced 3D printed pipe bender, Image ©2016 Markforged, Inc.
Volex 8 quadrotor photo and X-ray image Copyright © 2011-2016. www.3Ders.org All
Rights Reserved.
8 Conclusion
Part printed on a Solidoodle FDM printer © John Hart
Supply chain of the future article © IBM