Laminating (LOM) is one of the first additive manufacturing techniques created and uses a variety of sheet material, namely paper. Benefits include the use of A4 paper, which is readily available and inexpensive, as well as a relatively simple and inexpensive setup, when compared to others.
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The Ultrasonic Additive Manufacturing (UAM) process uses sheets of metal, which are bound together using ultrasonic welding. The process does require additional CNC machining of the unbound metal. Unlike LOM, the metal cannot be easily removed by hand and unwanted material must be removed by machining. Material saving metallic tape of 0.150mm thick and 25mm wide does however, result in less material to cut off afterwards. Milling can happen after each layer is added or after the entire process. Metals used include aluminium, copper, stainless steel and titanium. The process is low temperature and allows for internal geometries to be created. One key advantage is that the process can bond different materials and requires relatively little energy as the metal is not melted, instead using a combination of ultrasonic frequency and pressure (The Engineer, ). Overhangins can be built and main advantage of embedding electronics and wiring (Karunakaran et al., ). Materials are bonded and helped by plastic deformation of the metals. Plastic deformation allows more contact between surface and backs up existing bonds (Janaki Ram et al., ).
Post processing requires the extraction of the part from the surrounding sheet material. With LOM, cross hatching is used to make this process easier, but as paper is used, the process does not require any specialist tools and is time efficient. Whilst the structural quality of parts is limited, adding adhesive, paint and sanding can improve the appearance, as well as further machining.
Machine Example:
Machine
Area
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Layer Thickness
MCor Matrix 300 plus
A4 paper: 256 x 169 x 150 mm
0.1 mm ' 0.19 mm
Metal Additive Manufacturing (MAM) is a disruptive manufacturing technology that offers a whole world of possibilities. This is as true in terms of offering new levels of design freedom, as it is about the sheer choice of metal materials that can be used with metal 3D printers.
Take titanium as an example. Where conventional processes can be costly, Metal Additive Manufacturing can be an attractive technology for the processing of this advanced material, and others like it, such as alloys which can only be manufactured under high cooling rates.
Metal Additive Manufacturing opens a world of new applications and opportunities ' one great example is in the transportation sector, where it can enable lightweight engineering and design techniques, which are becoming more important in efforts not only to reduce, but also to redistribute a vehicle's mass, in order to save energy during use, reduce manufacturing costs or improve the working performance.
Metal Additive Manufacturing also allows for the cost-effective production of customized products in the medical and orthodontic sectors, that are personalized and 'tuned' to a patient's individual needs ' and this level of flexibility also points to the potential for use within the consumer goods market.
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