Optimization of Additive Manufacturing Processes Focused on 3D Printing

Abstract

Under the umbrella of Rapid-X (Udroiu & Ivan, 2008) there are some specific terms such as: Rapid Product Development (RPD), Rapid Technology, Rapid Nanotechnology, Rapid Prototyping (RP), Rapid Tooling (RT) and Rapid Manufacturing (RM). Additive manufacturing (AM) is an important component of the rapid product development process. Additive manufacturing technologies (AMT) represents a group of technologies used for building physical models, prototypes, tooling components and finished parts, all from three dimensional (3D) computer aided design (CAD) data or data from 3D scanning system. AMT involves automated fabrication of physically complex shapes directly from 3D CAD, using a layer-by-layer deposition principle. Based on AM principles, RP produces parts with limited functionality (prototypes and test parts), RM built end products and RT manufacture tools, jigs or moulds. Today's additive technologies offer advantages in many applications compared to classical subtractive fabrication methods like as milling, turning etc. Thus, parts can be formed with any geometric complexity or intricacy without the need for elaborate machine setup or final assembly. Also, AMT can lower manufacturing time of new products with 8-10 times in comparison with the conventional technologies and it reduces the costs of the products. There are a lot of additive manufacturing technologies in the world. The most popular AM technologies used worldwide are stereolithography (SL), selective laser sintering (SLS), Three dimensional printing (3DP), laminated object manufacturing (LOM), fused deposition modelling (FDM), polymer jetting (PolyJet), selective laser melting (SLM), direct metal laser sintering (DMLS), direct metal deposition (DMD), electron beam melting (EBM) and laser engineered net shaping (LENS). This chapter is focused on 3DP technologies that represent 44.3% of all additive systems installed worldwide at the end of 2005 (Wohler, 2006). The 3DP technologies (inkjet printing) can be classifying in the following main categories (Dimitrov et al., 2004): continuous printing (fused deposition modelling), drop on drop printing (polymer jetting) and drop on powder printing (3D Printing by ZCorp). The research was done under the umbrella of interdisciplinary platform PLADETINO (Platform for Innovative Technological Development), (Ivan, 2009). PLADETINO was aiming at create an interdisciplinary development and research centre regarding the innovation and the integration of the technologies of designing and manufacturing the products considering the new concepts (Rapid Manufacturing/ Prototyping, Reverse