Additive Manufacturing and Rapid Prototyping
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Questions and Answers

What is the primary driver of a country's economy according to the introduction?

  • The ability to respond quickly to changing customer demands
  • The reduction of production costs
  • The utilization of new innovative technologies
  • Development of new products with shorter development time (correct)

    • What is the primary characteristic of a prototype?

  • It is a model from which further models and eventually the final product will be derived (correct)
  • It is a model that can only be made from metals
  • It is the final version of a product
  • It is a model that can only be made from wood

    • What is the primary benefit of Rapid Prototyping compared to Traditional Prototyping?

  • It is more time-consuming
  • It gives better quality (correct)
  • It is more expensive
  • It is limited to a specific material

    • What is the primary definition of Rapid Prototyping?

    <p>A process for rapidly creating a system or part representation before final release or commercialization</p> Signup and view all the answers

    What is an alternative name for Rapid Prototyping?

    <p>Additive Manufacturing</p> Signup and view all the answers

    What is the primary advantage of Rapid Prototyping over Traditional Prototyping in terms of time?

    <p>It consumes less time</p> Signup and view all the answers

    What is the primary limitation of evaluating alternative design concepts in the product definition stage?

    <p>It can't effectively evaluate the alternative design concepts</p> Signup and view all the answers

    According to the Rapid Prototyping Wheel, what are the four primary areas of Rapid Prototyping?

    <p>Input, Method, Material, and Application</p> Signup and view all the answers

    Which of the following RP systems is classified as liquid-based?

    <p>3D Systems' Stereo lithography Apparatus (SLA)</p> Signup and view all the answers

    What is the primary material used in Electron Beam Melting (EBM)?

    <p>Titanium alloys</p> Signup and view all the answers

    What is the primary purpose of the low-pressure argon chamber in the LENSTM process?

    <p>To ensure good adhesion is accomplished</p> Signup and view all the answers

    What is the primary principle of the LENS process?

    <p>A high powered Nd: YAG laser focused onto a metal substrate creates a molten puddle</p> Signup and view all the answers

    What is the primary reason for creating an inert environment in SLS?

    <p>To minimize fire hazards due to high activation of fine particles</p> Signup and view all the answers

    What is the purpose of copper impregnation in another furnace after SLS?

    <p>To improve the polishability of the part</p> Signup and view all the answers

    What is the factor that decides the layer thickness in SL?

    <p>The power of the laser</p> Signup and view all the answers

    What is the purpose of the post-cure apparatus in SL?

    <p>To complete the polymerization</p> Signup and view all the answers

    What is the primary advantage of SLS over other 3D printing technologies?

    <p>Ability to use a wide variety of powders</p> Signup and view all the answers

    What is the limitation of SLS in terms of surface finish?

    <p>The finish is dependent on the particle size of the powder</p> Signup and view all the answers

    What is the primary function of the contra-rotating roller in SLS?

    <p>To level the powder layer</p> Signup and view all the answers

    What is the purpose of the mirror in SL?

    <p>To position the laser beam</p> Signup and view all the answers

    Why are explicit support structures required in SL?

    <p>To prevent the part from collapsing</p> Signup and view all the answers

    What is the primary advantage of SL over SLS?

    <p>SL has higher accuracy</p> Signup and view all the answers

    Which of the following processes is currently capable of producing only metal parts?

    <p>LENS process</p> Signup and view all the answers

    What is the primary advantage of the LENS process in terms of material properties?

    <p>Ability to produce fully dense metal parts</p> Signup and view all the answers

    What is the primary limitation of the Direct Metal Deposition (DMD) process?

    <p>Limited overhang angle</p> Signup and view all the answers

    What is the primary advantage of the Sheet Lamination (Laminated Object Manufacturing (LOM)) process?

    <p>Easy handling of the material</p> Signup and view all the answers

    What is the primary difference between the LENS process and the Direct Metal Deposition (DMD) process?

    <p>Layer formation process</p> Signup and view all the answers

    What is the primary advantage of the Direct Metal Deposition (DMD) process over traditional RP processes?

    <p>No waste material or subtractive processes necessary</p> Signup and view all the answers

    What is the primary drawback of the LOM process?

    <p>The time-consuming decubing operation</p> Signup and view all the answers

    What is the purpose of tilting the object by 10 to 15 degrees in LOM?

    <p>To avoid any surface becoming horizontal</p> Signup and view all the answers

    What is the advantage of using CO2 laser in LOM?

    <p>It is cheaper than other laser options</p> Signup and view all the answers

    What is the role of the hot roller in LOM?

    <p>To bond the layer to the previous layer</p> Signup and view all the answers

    What is the primary difference between SLS and 3D printing?

    <p>The use of a binder liquid</p> Signup and view all the answers

    What is the purpose of the twin heads in Fused Deposition Modeling (FDM)?

    <p>To create explicit support structures</p> Signup and view all the answers

    What is a characteristic of the material deposition process in Fused Deposition Modeling?

    <p>Droplets are shot by a nozzle onto a previously formed layer</p> Signup and view all the answers

    What is an advantage of Fused Deposition Modeling over other RP processes?

    <p>Any thermoplastic material can be used as long as the appropriate head is available</p> Signup and view all the answers

    What is a limitation of Fused Deposition Modeling?

    <p>As every point of the volume is addressed by a mechanical device, it is very slow</p> Signup and view all the answers

    What is unique about the way powder particles are heated in Electron Beam Melting?

    <p>Powder particles absorb electrons and gain kinetic energy</p> Signup and view all the answers

    Why is the powder bed required to be conductive in Electron Beam Melting?

    <p>To prevent the buildup of regions of negatively charged particles</p> Signup and view all the answers

    What is a characteristic of the Selective Laser Sintering process?

    <p>A laser is used to melt and fuse powder particles together</p> Signup and view all the answers

    Study Notes

    Introduction to Rapid Prototyping

    • Rapid prototyping (RP) is a class of technologies that create physical models from Computer-Aided Design (CAD) data.
    • Alternative names for RP include Additive Manufacturing, Layer Manufacturing, Direct CAD Manufacturing, and Solid Freeform Fabrication.

    Traditional Prototyping vs. Rapid Prototyping

    • Traditional prototyping involves building a model from clay, carving from wood, bending wire, or using thermoplastic, photopolymer, metals, paper, or titanium alloys.
    • Traditional prototyping methods are time-consuming, lack quality, and cannot effectively evaluate alternative design concepts.
    • Rapid prototyping methods are faster, more accurate, and can effectively evaluate design concepts.

    Classification of Rapid Prototyping Systems

    • RP systems can be classified into three categories: liquid-based, solid-based, and powder-based.

    Liquid-Based RP Systems

    • Liquid-based RP systems include:
      • 3D Systems' Stereo lithography Apparatus (SLA)
      • Cubital's Solid Ground Curing (SGC)
      • Sony's Solid Creation System (SCS)
      • CMET's Solid Object Ultraviolet-Laser Printer (SOUP)
      • Autostrade's E-Darts
      • Teijin Seiki's Soliform System
      • Meiko's Rapid Prototyping System for the Jewelry Industry
      • Denken's SLP
      • Mitsui's COLAMM
      • Fockele & Schwarze's LMS
      • Light Sculpting
      • Aaroflex
      • Rapid Freeze
      • Two Laser Beams
      • Micro fabrication

    Additive Manufacturing Techniques

      1. Laser Engineered Net Shaping (LENS)
      • Builds components in an additive manner from powdered metals using a Nd:YAG laser.
      • Produces fully dense metal parts with good metallurgical properties.
      • Advantages: superior material properties, complex parts, and reduced post-processing requirements.
      • Disadvantages: limited materials, large physical unit size, and high power consumption.
      1. Direct Metal Deposition (DMD)
      • Uses a laser to weld air-blown streams of metallic powders into custom parts.
      • Can produce fully dense metal parts with good metallurgical properties.
      • Advantages: ability to fabricate fully dense metal parts, efficient, and reduces production costs.
      • Disadvantages: limited to building overhang parts and requires support structures.
      1. Sheet Lamination (Laminated Object Manufacturing (LOM)
      • Builds parts by laminating layers of paper or other materials.
      • Advantages: fast, inexpensive, and ideal for patterns for casting.
      • Limitations: grid cutting takes time, decubing is time-consuming, and horizontal surfaces pose problems.
      1. 3D Printing
      • Similar to SLS, except that a binder liquid is sprayed in selected regions.
      • Can use a wide variety of powders.
      • Advantages: fast, inexpensive, and ideal for concept models.
      • Limitations: requires sintering, and supports are required.
      1. Fused Deposition Modeling (FDM)
      • Uses molten material to build parts.
      • Advantages: uses any thermoplastic material, easy to remove support, and inexpensive.
      • Limitations: slow, not very accurate, and requires explicit support structures.
      1. Electron Beam Melting (EBM)
      • Uses an electron beam to induce fusion between metal powder particles.
      • Advantages: fast, efficient, and can process conductive materials.
      • Limitations: can only be used with conductive materials, and has a larger heat-affected zone.
      1. Selective Laser Sintering (SLS)
      • Uses a laser to fuse together metal powder particles.
      • Advantages: fast, uses a wide variety of powders, and ideal for making injection molding tools.
      • Limitations: surface finish is poor, and Z accuracy is poor.
      1. Photopolymerization (Stereo Lithography (SLA)
      • Uses a laser to polymerize liquid photopolymer.
      • Advantages: fast, accurate, and ideal for making prototypes.
      • Limitations: requires explicit support structures, and post-processing is required.

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    Description

    Explore the basics of additive manufacturing, including rapid prototyping, materials, applications, limitations, and classification of rapid manufacturing processes. Understand the differences between traditional and rapid prototyping.

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