Direct manufacturing creates 3D objects from liquid or powder using a laser or narrow nozzles. Digitized designs are fed into a computer to control the process. It can be used for prototypes or end-user items and is suitable for short or uncertain production runs. DM can create complex designs that are difficult to make with other methods.
Direct manufacturing (DM), also known as additive or rapid manufacturing, is a process that creates a solid, three-dimensional (3D) object from liquid or powder. This can be accomplished by hitting the substance with a laser or other form of beam, such as an electron beam, or by directing it in molten form through extremely narrow nozzles. Digitized designs, such as those created in computer-aided design (CAD) programs, are fed into a computer that controls the process and creates the final product.
Direct manufacturing can be simplistically characterized as “3D printing”. The operation may resemble that of a classic inkjet printer, but it works in three dimensions. Like traditional printing, once the design is sent to the computer, the rest of the process is handled without human interaction.
The types of direct processing can be divided into two broad categories: those in which molten material is deposited and those in which layers of material are acted upon. In the former, the molten material, usually a plastic, is extruded through nozzles, none much wider than a human hair. The filaments are arranged, one layer at a time, according to the CAD drawing, with a typical layer measuring 0.005 inch (0.0127 cm) thick.
In the case of material to be treated, a thin layer of powder is spread, usually using a roller. Then a layer of the CAD drawing is etched into the powder with a laser or other beam of energy. The dust particles are fused into the shape of the beam path, creating a single layer of the design. The process is then repeated until the item is complete.
Specialty or limited-production items are often more suitable for direct production, such as prototypes or parts for spacecraft or military aircraft with unusual geometries. In creating end-user items, some companies working with DM methods claim that the process is competitive with traditional injection molding and machining techniques. When deciding between DM and another manufacturing process, you need to consider production volume, design complexity, and likelihood of change.
Due to the prohibitive costs of molds and machined parts required for traditional manufacturing, direct manufacturing can be suitable for short or uncertain production runs. It can be used for other products once the intended run is over. For very complex designs, DM may be able to create one-piece items that would be difficult or even impossible to create with most other manufacturing methods.
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