1. Future Challenges
Complexity – more materials, greater integration, personalisation, increased use of biologics
Maintaining or reducing costs – automation, disruptive manufacturing approaches
Building new business models – retaining value in Europe
New products and services - recognising consumer demands before they do

2. Advanced Manufacturing Processes
Customisation
Composite manufacture
Manufacturing processes for renewable raw materials, biomaterials and cell based products
Joining technologies for advanced and multi-materials
Delivery of new functionalities through (mass production) surface manufacturing processes
Manufacturing of flexible structures
Product life cycle management for advanced materials

3. What is Additive Manufacturing? (3D Printing)
The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies

4. Rapid prototyping, noun – additive manufacturing of a design, often iterative, for form, fit or functional testing or combination thereof.

5. Vat Photopolymerization
Types of Aditive Manufacturing
Vat Photopolymerization
An additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerization.
Stereolithography
Envisiontec
Micro-SLA …

6. Material Jetting
An additive manufacturing process in which droplets of build material are selectively deposited
Wax or Photopolymers
Multiple nozzles
Single nozzles …

7. Binder Jetting
An additive manufacturing process in which a liquid bonding agent is selectively deposited to join powder materials.
Zcorp
Voxeljet
ProMetal/ExOne …

8. Material Extrusion
An additive manufacturing process in which material is selectively dispensed through a nozzle or orifice
From microns to meters
Stratasys FDM machines
Office friendly
DIY community
Best selling platform …

9. Powder Bed Fusion
An additive manufacturing process in which thermal energy selectively fuses regions of a powder bed
SLS, SLM, DMLS, EBM, etc.
Polymers, metals & ceramics

10. Sheet Lamination
An additive manufacturing process in which sheets of material are bonded to form an object.
Paper (LOM)
Using glue
Plastic
Using glue or heat
Metal
Using welding or bolts
Ultrasonic AM…

11. Directed Energy Deposition
An additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited
Wire & Powder Materials
Lasers & Electron Beams
Great for feature addition & repair

12. Medical imaging

13. Dentistry
Paleontology

14. Architecture and Design
Morongo Casino, Palm Springs, Model

15. Entertainment Modeling

16. Automotive

17. Advanced Composite Process
Pultrusion

19. Advance Joining Process
Friction welding
-Friction heat caused by the motion of one surface against another enables plastic deformation and atomic diffusion at the interface
-Used by the automotive industry for decades in the manufacture of a range of components
-The weld is formed across the entire cross-sectional area of the interface in a single shot process

20. Direct or continuous drive
Rotary Friction Welding
Linear Friction Welding
Friction stir welding
Direct or continuous drive
Pre-determined time of motion determined by the size and type of material

21. Linear friction welding
±1-3mm
Frequency Hz
Maximum axial force 150kN

22. Friction stir welding

23. Bottom Up technique uses chemical and physical interactions
Advanvced Functional Material Process
example nanomaterials
Top Down technique uses large machines to make the nanostructures from larger materials
Example: Photolithography to make Computer Processor Chips
Bottom Up technique uses chemical and physical interactions
to make nanostructures without
guidance
Example: Catalyst to make Carbon Nanotubes

24. Smart Materials are manufactured goods that react to some outside forces. Crystals can expand and contract with electricity, metals can retain a shape memory, liquids can move with magnetic fields, and surface cracks can heal themselves.

25. Processing of biomaterials