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Dwight Mitchell • 4 July 2022

What Is Additive Manufacturing? Ultimate Guide to Additive Manufacturing: 7 Main Technologies Explained


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Additive manufacturing (or additive technology, as it is also known) is a group of processes that directly fabricate final parts from digital models. It goes beyond simply 3D printing small volumes of prototypes or short-run production parts. Rather, it involves creating entire objects or structures by adding material (in this case, plastics, metals, and even liquids), layer upon layer, to create the finished part. Explaining additive manufacturing in simple terms isn’t easy. There are several different ways additive technology can be used to build things from scratch—and each has its own pros and cons. Some methods are more effective for a certain type of design than others; some are better suited to small runs than others; some cost less than others; some are faster than others… you get the picture!

 

Modular manufacturing is a type of additive manufacturing where parts are built up from a series of units that are put together. The concept is simple: material is added to create a finished product from a digital file. 3D printing services use this technology to create 3D models on demand. This process begins with a 3D model created in CAD software. The 3D model is then converted into a digital file and sent to a 3D printer. The 3D printer creates the part by adding materials layer by layer according to the digital file. 3D printed parts can be used for marketing and promotion, or they can be used as functional parts in products. Additive manufacturing is a powerful technology that offers several advantages over traditional manufacturing methods. For example, additive manufacturing does not require expensive tools or molds, and it can be used to create complex shapes that would be difficult or impossible to produce using traditional methods. As a result, additive manufacturing is changing the landscape of manufacturing, and it is likely to have a significant impact on the economy in the years to come. When you build something by adding materials together one layer at a time, you are using additive manufacturing. If a part is built up from a series of units that are put together, this is also known as modular manufacturing. The concept is simple: material is added to create a finished product from a digital file. However, the reality of additive manufacturing is much more complex. While there are several ways to achieve this additive manufacturing effect, the basic idea is the same.

 

3D Printing vs. Additive Manufacturing

The biggest difference between 3D printing and additive manufacturing is the way in which the object is created. 3D printing involves building an object up layer by layer using a vat of liquid material that is shaped by a moving platform on which the object is built. The machine then leaves the item in the liquid to dry before the next layer is added. In additive manufacturing, on the other hand, the object is built from a thin stream of material that is sprayed out through a nozzle in a controlled manner. The layers of material are deposited directly on top of each other until the part is finished. Both technologies can be used for a wide range of applications and industries, but their primary difference is in how the parts are built. 3D printing is a type of additive manufacturing where an object is created by depositing material one layer at a time. 3D printers are typically slower than other additive manufacturing methods and have lower resolutions. However, 3D printing is well-suited for prototyping and small batch production due to its lower costs and ease of use. 3D printing services are often used for marketing and promotion, as 3D models can be quickly created and customized on demand. 3D printing can also be used to create functional parts and end-use products, although the process is generally not as efficient as other manufacturing methods for high-volume production. Additive manufacturing refers to a broad range of technologies that all share the common theme of building objects by adding material layer by layer. These technologies include 3D printing, but also encompass a wider range of processes such as 3D milling, 3D sintering, direct energy deposition, and stereolithography. Additive manufacturing is more versatile than 3D printing and can be used to create objects with a wide range of properties and functionality. However, additive manufacturing is generally more expensive and complex than 3D printing, making it less suitable for low-cost prototyping and small batch production.


Hover  over  the images  below  to  see  some of the various types  of Additive Manufacturing process.

The 7 Main Types of Additive Manufacturing

  1. 3D printing is one type of additive manufacturing. The other 6 types of additive manufacturing are outlined below.
  2. Vat Photopolymerization (VP) - VP is a form of SL technology that uses UV light to solidify a photopolymer resin contained in a vat. In order to build an object, the resin is selectively cured by a light source, which creates an open-air environment within the vat. The liquid is also agitated to ensure the resin is distributed evenly throughout the volume of the vat. After the light is switched off, the liquid becomes solid and can be removed from the vat.

3.   Material Extrusion (ME) - ME is the process of transforming materials that are fed through a hopper into a thin, continuous material stream that is cut into a controlled length. The material is then pushed through a sheath to create a melt-blown web that can be deposited onto a build tray and cured with a single shot of infrared light. The technique is commonly used to create large, single-piece structures that can be used in infrastructure projects, vehicle design, and architecture.

4.   Material Jetting (MJ) - MJ is a form of SL in which a computer controls the rate at which a polymer is fed through an inkjet-like nozzle to form a thin, continuous stream of material. The material is then deposited onto a build tray and cured with a single shot of ultraviolet light.

       MJ technology is used to create large-scale, single-piece structures that can be used in architecture and construction projects, as well as         industrial manufacturing.

5.  Binder Jetting (BJ) - BJ is a form of SL that uses a computer-controlled binder jetting machine to precisely dispense binding agents onto a build tray and create a fully-cured object. The raw materials are first fed through an inkjet-like nozzle, where they are mixed with a binding agent and then deposited onto a build tray. The binding agent is then cured with a single shot of ultraviolet light to create a solid part. BJ technology is used to manufacture small- to medium-scale objects, such as medical devices and consumer goods.

6.   Powder Bed Fusion (PBF) - PBF is a form of SP that uses a rotating drum to create a thin, even layer of metal powder. The powder is distributed evenly across the rotating drum and deposited onto a build tray. The powder bed is then heated to the melting point of the metal and a liquid feedstock is sprayed across the rotating drum. The liquid metal is drawn into the powder bed and the two materials are fused together, forming a solid part. This is similar to the technique used in metal casting, except that it is done in a controlled, closed environment using a liquid metal feedstock.

7.   Directed Energy Deposition (DED) - DED is a form of SP that uses a focused laser beam to create a thin, even layer of metal powder. The powder is distributed evenly within a rotating drum and deposited onto a build tray. The powder bed is then heated to the melting point of the metal and a liquid feedstock is sprayed across the rotating drum. The liquid metal is drawn into the powder bed and the two materials are fused together, forming a solid part.

 

Summing up

In short, additive manufacturing is a group of processes that directly fabricate final parts from digital models. It goes beyond simply 3D printing small volumes of prototypes or short-run production parts. The concept is simple: material is added to create a finished product from a digital file. However, the reality of additive manufacturing is much more complex. While there are several ways to achieve the additive manufacturing effect, the basic idea is the same. The biggest difference between 3D printing and AM is the way in which the object is created. 3D printing involves building an object up layer by layer using a vat of liquid material that is shaped by a moving platform on which the object is built. The machine then leaves the item in the liquid to dry before the next layer is added. In additive manufacturing, on the other hand, the object is built from a thin stream of material that is sprayed out through a nozzle in a controlled manner. The layers of material are deposited directly on top of each other until the part is finished.

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