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A D D i t i v e M A n U F A c t U r i n G Figure 1. The principle of additive manufacturing on the example of laser sintering, in which a laser is used to build parts layer by layer based on a computer model Digital Layer Construction SyLVIA MONSHEIMER Additive manufacturing holds untapped potential, particularly for low-volume production. extrusion and injection molding are not always the best way to mold plastics. An alternative is moldfree production, which combines maximum flexibility with high customer orientation and cost efficiency. with laser sintering, for example, it can produce complex and technically demanding industrial and consumer goods. M ost pathbreaking technologies are based on one simple and persuasive idea. The same is true of methods for mold-free production of parts—experts also refer to this as rapid manufacturing, rapid prototyping, additive manufacturing, and additive fabrication. These buzzwords are based on one principle: liquids, powders, strands and films are layered to build three-dimensional structures without the use of a mold. In the laser sintering process, which requires powdered starting material, containers are filled with fine metal, ceramic or plastic powder. A laser located above the powder bed, and precision-guided by CAD software and suit able optics, lights only certain areas of the uppermost particle layer. These areas melt and solidify after cooling. An automatic mechanism then low ers the Laser Roller Fabrication Powder delivery system powder bed Scanner system Laser scanning direction Sintered powder particles Object being fabricated Powder delivery piston Fabrication piston floor of the powder container by fractions of millimeters, and spreads a fresh layer of parti cles. Again, the laser lights this layer only in certain places (Fig. 1). The result of this method is a spatial component built of ultra-thin layers, whose complexity is limited by almost nothing but the specified electronic construction data. This free-form fabrication uses no casting molds, tools or space consuming production plants. Additive manufacturing (AM), therefore, is the counterpart to conventional methods, in which parts are molded into specified forms, for example, or cut from a massive block. With AM, components are created directly from a digital construction plan. This enables the production of forms that have been long considered impossible by con ventional series production—in fact, they can be created fast, flexibly, and with fewer machines. >>> Laser beam Laser sintering Pre-placed powder bed Unsintered material in previous layers Source: Materialgeeza/Wikipedia 18 elements32 evonik science newsletter
elements32 evonik science newsletter D e S i G n i n G w i t H P o l Y M e r S The FinGripper of Festo AG & Co. KG, Esslingen, which specializes in automation engineering. Produced by selective laser sintering, the FinGripper is light, flexible and adaptable. Like the human hand, it adjusts itself to the shape of the object to be gripped, KG which allows fast and safe handling of ripe Co. fruit, bulbs and pressure-sensitive foods. & The FinGripper is produced by applying layers AG of polyamide powder 0.1 millimeters thick on top of each other and selectively melting Festo them by laser. The result, after cooling, is a solid component Photo: 19
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