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ADDITIVE MANUFACTURING ADDITIVE MANUFACTURING Edited by Amit Bandyopadhyay Susmita Bose Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Group, an informa business MATLAB® and Simulink® are trademarks of The MathWorks, Inc. and are used with permission. The MathWorks does not warrant the accuracy of the text or exercises in this book. This book’s use or discussion of MATLAB® and Simulink® software or related products does not constitute endorsement or sponsorship by The MathWorks of a particular peda- gogical approach or particular use of the MATLAB® and Simulink® software. CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2016 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Version Date: 20150717 International Standard Book Number-13: 978-1-4822-2360-6 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the valid- ity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. 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Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com Contents Preface ............................................................................................................................................vii Editors ..............................................................................................................................................ix Contributors ....................................................................................................................................xi 1. Global Engineering and Additive Manufacturing ..........................................................1 Amit Bandyopadhyay, Thomas PL. Gualtieri, and Susmita Bose 2. Additive Manufacturing Technologies for Polymers and Composites .....................19 Ranji Vaidyanathan 3. Deposition-Based and Solid-State Additive Manufacturing Technologies for Metals ...............................................................................................................................65 Vamsi Krishna Balla 4. Additive Manufacturing of Metals Using Powder-Based Technology .....................97 Michael Jan Galba and Teresa Reischle 5. Additive Manufacturing of Ceramics ............................................................................143 Susmita Bose, Sahar Vahabzadeh, Dongxu Ke, and Amit Bandyopadhyay 6. Design Issues in Additive Manufacturing ....................................................................185 Gaurav Ameta 7. Bioprinting: Application of Additive Manufacturing in Medicine .........................197 Forough Hafezi, Can Kucukgul, S. Burce Ozler, and Bahattin Koc 8. Multifunctional Printing: Incorporating Electronics into 3D Parts Made by Additive Manufacturing .............................................................................................215 Dishit Paresh Parekh, Denis Cormier, and Michael D. Dickey 9. Industrial Implementation of Additive Manufacturing ............................................259 Edward D. Herderick and Clark Patterson 10. Additive Manufacturing for the Space Industry .........................................................277 Christian Carpenter 11. Additive Manufacturing and Innovation in Materials World ..................................297 Mitun Das and Vamsi Krishna Balla 12. Additive Manufacturing in Education ...........................................................................333 Kirk A. Reinkens v vi Contents 13. Personalized Implants and Additive Manufacturing .................................................351 Mukesh Kumar and Bryan Morrison 14. Additive Manufacturing: Future of Manufacturing in a Flat World .......................367 Amit Bandyopadhyay and Susmita Bose Index .............................................................................................................................................377 Preface The field of additive manufacturing has seen explosive growth in recent years due to renewed interest in the manufacturing sector in the United States and other developed as well as developing nations. The experience of drawing something in a computer and then seeing that part being printed in a 3D printer that can be touched or felt is still fascinating to many of us. And now we are seeing the same in our children, who are only in their middle school or high school and yet experiencing the revolution of additive manufacturing/3D printing through their own creation. Such transformative change in our society has been made possible only because of a significant reduction in the price of a 3D printer and improvement in part quality. As recently as 10 years back, a good 3D printer cost more than $100,000 in the United States. Due to the high cost of the 3D printers, most people were only able to see a picture or a video of different 3D printers. As the cost of the printer came down significantly along with improvements in 3D printer reliability and part quality, most businesses, universities, and schools are investing in 3D printers to experience, explore, and innovate with these fascinating additive manufacturing technologies. Therefore, we felt that our book will be quite timely as we have tried to capture some of the exciting developments of 3D printing or additive manufacturing technologies in recent years toward advanced materials. We understand that there are a few other books that deal with additive manufacturing in some form. When we reviewed the literature, we realized that a majority of those books were developed by mechanical engineers, who placed special emphasis on printers rather than on their applications. However, at present, most of the printing technology is quite mature and a majority of the current innovation lies in the areas of their applications. Therefore, our work focuses more on the applications of additive manufacturing than on core 3D printing technologies. Our hope is that readers will be able to see how these technologies are currently being used and then contribute to the field with their own innovation. We have designed the book in a way that can be used in a classroom setting as well. The first few chapters focus on an introduction to various additive manufacturing technologies based on their utilization towards different classes of materials. The next set of chapters discusses important application areas of additive manufacturing. Finally, some discussion on educational aspects and regulatory issues has been added since those fac- tors are becoming important with the emergence of additive manufacturing as a mature technological platform for many industries. Like any edited book, we recognize all authors, without their help our project would have never been completed. We sincerely thank them for their contributions. We thank many of our students for their support toward developing this book, particularly Tom Gualtieri, Sahar Vahabzadeh, and Dongxu Ke. We would also like to acknowledge support from both our boys, Shohom and Aditya, without which we could not have completed this work. vii viii Preface Even after working in this area for the past 20 years, we still learn new things regularly related to the applications of additive manufacturing. We hope that our book will be useful to many veteran researchers as well as those who are entering this field, helping them understand the subject better to contribute toward making a difference to our future generation. Amit Bandyopadhyay and Susmita Bose Washington State University MATLAB® is a registered trademark of The MathWorks, Inc. For product information, please contact: The MathWorks, Inc. 3 Apple Hill Drive Natick, MA 01760-2098 USA Tel: +1 508 647 7000 Fax: +1 508 647 7001 E-mail: [email protected] Web: www.mathworks.com Editors Amit Bandyopadhyay, a Herman and Brita Lindholm Endowed Chair Professor in the School of Mechanical and Materials Engineering at Washington State University (WSU), received his BS degree in metallurgical engineering from Jadavpur University (Kolkata, India) in 1989, an MS degree in metallurgy from the Indian Institute of Science (Bangalore, India) in 1992, and a PhD in materials science and engineering from the University of Texas at Arlington (Arlington, TX) in 1995. In 1995, he joined the Center for Ceramic Research at Rutgers University for his postdoctoral training. In 1997, he joined WSU as an assistant professor, and was promoted to an associate level in 2001, then to the full p rofessor level in 2006. His research expertise is focused on additive manufacturing of hard materials toward structural and biomedical applications. He has communicated over 250 technical articles. He holds 11 US patents, edited 8 books, and has supervised over 35 graduate students for their degrees in physics, mechanical engineering, and materials science and engineering. Among others, Professor Bandyopadhyay received the CAREER award from the US National Science Foundation and the Young Investigator Program award from the US Office of Naval Research. Professor Bandyopadhyay is a fellow of the US National Academy of Inventors, the American Ceramic Society, the American Society for Materials, the American Institute for Medical and Biological Engineering, and the American Association for the Advancement of Science. He has been working in the areas of additive manufacturing of advanced materials since 1995. Susmita Bose, a Herman and Brita Lindholm Endowed Chair Professor in the School of Mechanical and Materials Engineering (MME) at Washington State University (WSU), received her BS degree from Kalyani University (India) in 1990, an MS from the Indian Institute of Technology (IIT)—Kanpur in 1992, and a PhD from Rutgers University, New Jersey, in 1998 in Physical Organic Chemistry. In 1998 she joined the MME, WSU, as a research assistant scientist in materials science and engineering, and since then she has been working with rapid prototyping/3D printing of bone tissue engineering scaffolds with controlled chemistry, especially with calcium phosphates, surface modification of metallic implants, and drug delivery. In 2001, she started as an assistant professor in MME, she was promoted to associate professor in 2006, and to full professor in 2010. Her awards include the prestigious Presidential Early Career Award for Scientist and Engineers (PECASE, the highest honor given to a young scientist by the US president at the White House) from the US National Science Foundation in 2004, the Schwartzwalder-Professional Achievement in Ceramic Engineering (PACE) award in 2009, and Richard M. Fulrath award in 2014 from the American Ceramic Society. Dr. Bose was named as a “Kavli Fellow” by the US National Academy of the Sciences. She has supervised over 30 graduate students in materials science and engineering (MSE), mechanical engineering, chemistry, and bioengineering. Dr. Bose has published over 220 technical papers, edited 6 books, and holds 3 US patents. Dr. Bose is a fellow of the American Institute for Medical and Biological Engineering and the American Ceramic Society. Dr. Bose’s group research on 3D printed bone tissue engineering scaffolds with controlled chemistry has been featured by the AP, BBC, NPR, CBS News, MSNBC, ABC News, and many other TV, radio stations, magazines, and news sites all over the world. ix