Fundamentals of Additive Manufacturing for the Practitioner

Sheku Kamara is Dean of Applied Research at Milwaukee School of Engineering, where he supervises the school’s Applied Technology Center. He is past Chair of the Additive Manufacturing Users Group and co-managed the development of the Additive Manufacturing Body of Knowledge and the Additive Manufacturing Certificate Program for SME and America Makes.Kathy S. Lassila, PhD, is former Director of Graduate and Professional Studies at Milwaukee School of Engineering and served as Associate Director of Curriculum and Programs for Business and Technology at Capella University. She co-authored the Additive Manufacturing Body of Knowledge and the Additive Manufacturing Certificate Program for SME and America Makes.

• Chapter 1 Introduction: Moving into Additive Manufacturing 1Introduction 2Manufacturing Processes 5Traditional and AM Job Roles 8How to Use This Book 20References 20Chapter 2 Is Additive Manufacturing the Right Solution? 21Introduction 22Additive Manufacturing Applications 23A Brief History of AM 33Selecting a Pilot AM Project 35References 41Chapter 3 What Design and Inputs Does Additive Manufacturing Require? 43Introduction 44Design for AM 45Design for DFAM 45Component Design 47Part Design 50Process Design 57Sources of Input 58AMF and STL File Formats 59References 63Chapter 4 What Materials Does Additive Manufacturing Use? 65Introduction to AM Materials 66Selecting AM Materials 67Polymers 69References 82Chapter 5 Which Additive Manufacturing Technology and Process Are Right for My Solution? 85Introduction 86Binder Jetting 88Directed Energy Deposition 90Material Extrusion 92Material Jetting 94Powder Bed Fusion 96Sheet Lamination 98Vat Photopolymerization 99Hybrid Systems 102References 103Chapter 6 What Machine and Build Preparation Occurs in Additive Manufacturing? 105Introduction 106General Machine and Build Preparation Tasks 107AM Process-Specific Machine and Build Preparation 111References 122Chapter 7 What Occurs During the Additive Manufacturing Build Process? 123Introduction 124Quality in AM 124Build Planning and the Build Process 128Build Process 133References 138Chapter 8 What Happens after the Additive Manufacturing Build Process Is Complete? 141Introduction 142Part Removal 143Material Removal 144Support Removal 146Treating 147Finishing 147Inspection 148Summary of Post-Processing Methods 148References 150Chapter 9 What Do We Do to Move to Additive Manufacturing? 153Introduction 153AM Implementation Roadmap 154Identify a Vision and Strategy 155Prepare to Manage Change 157Acquire AM Systems Access and Support 158Develop AM Workflows 161Develop Your AM Workforce 162Monitor Results and Adjust 164References 165Chapter 10 Where Can I Learn More? 167Introduction 167AM Acronyms and Terminology 167AM Job Postings and Employment Information 168AM Education and Training 169 AM Professional Certification 170AM Body of Knowledge (AMBOK) 170AM University Consortia and Centers of Excellence 171AM Service Bureaus and Vendors 171AM Material Selection Guides 172AM Technology Selection Guides 172AM Design Guidelines 173AM Professional Associations, Conferences, and Meetings 173Index 175

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