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Material Extrusion and Vat Photopolymerization—Principles, Opportunities and Challenges

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Additive Manufacturing for Chemical Sciences and Engineering

Abstract

The additive manufacture (AM) of plastic components can be accomplished by a variety of methods which are classified according to how material layers are consolidated layer-by-layer to create physical objects from digital data. Two of the most widely used methods include Material Extrusion (MEX) and Vat Photopolymerization (VP). These methods include a range of commercialized AM processes often referred to by various trademarked terms such as Fused Deposition Modelling (FDM) and Stereolithography (SLA). Compared to conventional subtractive or formative manufacturing process, MEX and VP are able to manufacture complex parts with high ability for customization, as they impose few constraints on part geometry, and require low setup effort with no custom tooling. Furthermore, MEX and VP are both well-established additive manufacturing processes and through ongoing refinement have achieved compatibility with a broad range of materials and part geometries, and comparatively low operating costs. Due to their high versatility, MEX and VP have been widely used in a broad range of industries including applications in chemical sciences, biotechnology, aerospace, defense, and automotive engineering. However, despite their high versatility, AM processes such as MEX and VP are subject to unique technological characteristics associated with the manufacturing process, the material properties, part design and suitable application areas. This chapter provides an overview of MEX and VP processes characteristics critical to the effective application of these additive manufacturing technologies to high performance products.

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Abbreviations

AM:

Additive Manufacturing

ABS:

Acrylonitrile Butadiene Styrene

ASTM:

American Society for Testing and Materials

BAAM:

Big Area Additive Manufacturing

CLIP:

Continuous Liquid Interface Production

DIW:

Direct Ink Writing

DLP:

Digital Light Processing

FDM:

Fused Deposition Modelling

ISO:

International Organization for Standardization

MEAM:

Material Extrusion-based Additive Manufacturing

MIM:

Metal Injection Moulding

PBT:

Polybutylene terephthalate

PC:

Polycarbonate

PCL:

Polycaprolactone

PGA:

Polyglycolic acid

PIM:

Powder Injection Moulding

PLA:

Polylactic acid

PS:

Polystyrene

SDS:

Shaping Debinding and Sintering

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Authors and Affiliations

  1. Centre for Advanced Materials and Industrial Chemistry, RMIT University, Melbourne, VIC, Australia

    PR. Selvakannan

  2. Centre for Additive Manufacturing, RMIT University, Melbourne, VIC, Australia

    Maciej Mazur & Xiaochen Sun

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  1. PR. Selvakannan
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  2. Maciej Mazur
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  3. Xiaochen Sun
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Correspondence to PR. Selvakannan .

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Editors and Affiliations

  1. Centre for Advanced Materials and Industrial Chemistry, RMIT University, Melbourne, VIC, Australia

    Suresh K. Bhargava

  2. Centre for Nanofibers and Nanotechnology, National University of Singapore, Singapore, Singapore

    Seeram Ramakrishna

  3. Centre for Additive Manufacturing, RMIT University, Melbourne, VIC, Australia

    Milan Brandt

  4. Centre for Advanced Materials and Industrial Chemistry, RMIT University, Melbourne, VIC, Australia

    PR. Selvakannan

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Selvakannan, P., Mazur, M., Sun, X. (2022). Material Extrusion and Vat Photopolymerization—Principles, Opportunities and Challenges. In: Bhargava, S.K., Ramakrishna, S., Brandt, M., Selvakannan, P. (eds) Additive Manufacturing for Chemical Sciences and Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-19-2293-0_3

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