Podcast
Questions and Answers
What is the primary purpose of converting a CAD model to STL format?
What is the primary purpose of converting a CAD model to STL format?
- To create a detailed engineering drawing
- To export as a 3D printing file
- To simplify the model's geometry for AM (correct)
- To enhance the visual quality of the model
The conversion to STL format is a manual process requiring significant user intervention.
The conversion to STL format is a manual process requiring significant user intervention.
False (B)
Name one application area of additive manufacturing that does not involve conventional CAD modeling.
Name one application area of additive manufacturing that does not involve conventional CAD modeling.
Medical modeling
The eight steps in the additive manufacturing process include conceptualization and CAD, conversion to STL, transfer and manipulation of STL file, _____, build, part removal and cleanup, post-processing of part, and application.
The eight steps in the additive manufacturing process include conceptualization and CAD, conversion to STL, transfer and manipulation of STL file, _____, build, part removal and cleanup, post-processing of part, and application.
Match the type of additive manufacturing system with its description:
Match the type of additive manufacturing system with its description:
What are common considerations in the design for additive manufacturing?
What are common considerations in the design for additive manufacturing?
Energy density is an important factor in metal additive manufacturing systems.
Energy density is an important factor in metal additive manufacturing systems.
What is one of the initial actions required prior to building a part?
What is one of the initial actions required prior to building a part?
What is the significance of part removal and cleanup in the additive manufacturing process?
What is the significance of part removal and cleanup in the additive manufacturing process?
All AM machines must run a variety of materials with numerous setup parameters.
All AM machines must run a variety of materials with numerous setup parameters.
What is the purpose of repositioning the part before building?
What is the purpose of repositioning the part before building?
Parts may require _____ or coating allowances.
Parts may require _____ or coating allowances.
Match the following actions with their related descriptions:
Match the following actions with their related descriptions:
During which phase does the process switch to computer-controlled building?
During which phase does the process switch to computer-controlled building?
All AM machines alert the user when the build is complete or when there is no source material remaining.
All AM machines alert the user when the build is complete or when there is no source material remaining.
What does significant manual finishing typically entail for parts produced by AM machines?
What does significant manual finishing typically entail for parts produced by AM machines?
What is the role of support structures in additive manufacturing?
What is the role of support structures in additive manufacturing?
Post-processing tasks always require the use of power tools.
Post-processing tasks always require the use of power tools.
What are some common post-processing techniques used in additive manufacturing?
What are some common post-processing techniques used in additive manufacturing?
AM materials often have small _____ trapped inside them, leading to potential failure under stress.
AM materials often have small _____ trapped inside them, leading to potential failure under stress.
What is a potential consequence of poor technique in support removal?
What is a potential consequence of poor technique in support removal?
Match the additive manufacturing issues with their descriptions:
Match the additive manufacturing issues with their descriptions:
Many applications using AM processes do not require high performance from their _____ .
Many applications using AM processes do not require high performance from their _____ .
Why may parts produced by additive manufacturing behave differently than those made by conventional methods?
Why may parts produced by additive manufacturing behave differently than those made by conventional methods?
What is the nominal layer thickness range for most SL technology machines?
What is the nominal layer thickness range for most SL technology machines?
Thicker layers in additive manufacturing (AM) lead to parts being built more precisely.
Thicker layers in additive manufacturing (AM) lead to parts being built more precisely.
What material property must be considered during post-processing that involves heat?
What material property must be considered during post-processing that involves heat?
In powder-based systems, there is no need to use _____ .
In powder-based systems, there is no need to use _____ .
Match the following AM technologies with their characteristics:
Match the following AM technologies with their characteristics:
What is an advantage of photopolymer-based systems?
What is an advantage of photopolymer-based systems?
Newer resins in photopolymer systems offer improved temperature resistance and strength.
Newer resins in photopolymer systems offer improved temperature resistance and strength.
What type of machine typically has a nominal layer thickness of 0.254 mm?
What type of machine typically has a nominal layer thickness of 0.254 mm?
What is a key requirement for molten material systems that melt and deposit materials in a molten state?
What is a key requirement for molten material systems that melt and deposit materials in a molten state?
Extrusion processes like FDM always generate supports automatically.
Extrusion processes like FDM always generate supports automatically.
What is one of the challenges faced when cleaning parts produced by lamination methods?
What is one of the challenges faced when cleaning parts produced by lamination methods?
Exposure to _____ and excessive light should be avoided in material handling.
Exposure to _____ and excessive light should be avoided in material handling.
Match the following application areas with their respective technology:
Match the following application areas with their respective technology:
Which of the following is NOT a factor to consider in metal systems?
Which of the following is NOT a factor to consider in metal systems?
List two design considerations for additive manufacturing.
List two design considerations for additive manufacturing.
Some machines in additive manufacturing must be kept away from _____ environments.
Some machines in additive manufacturing must be kept away from _____ environments.
Which of the following is a type of Vat Photopolymerization process?
Which of the following is a type of Vat Photopolymerization process?
Two-Photon Vat Photopolymerization offers only advantages and no drawbacks.
Two-Photon Vat Photopolymerization offers only advantages and no drawbacks.
What is one of the key components of photopolymer chemistry?
What is one of the key components of photopolymer chemistry?
The process that models irradiance and exposure in Vat Photopolymerization is known as _____ .
The process that models irradiance and exposure in Vat Photopolymerization is known as _____ .
Match the following scan patterns with their descriptions:
Match the following scan patterns with their descriptions:
Which of the following radiation types is primarily used to cure commercial photopolymers?
Which of the following radiation types is primarily used to cure commercial photopolymers?
Epoxy and vinylether are examples of free radical polymerization.
Epoxy and vinylether are examples of free radical polymerization.
What is the role of a photoinitiator in photopolymerization?
What is the role of a photoinitiator in photopolymerization?
Photopolymer resins must be cleaned, post-cured, and _____ after building.
Photopolymer resins must be cleaned, post-cured, and _____ after building.
Match the following photopolymerization processes with their respective characteristics:
Match the following photopolymerization processes with their respective characteristics:
What component of the laser scan VP machines is responsible for liquid resin application?
What component of the laser scan VP machines is responsible for liquid resin application?
Both di-functional and higher functionality monomers are commonly used in SL resins.
Both di-functional and higher functionality monomers are commonly used in SL resins.
Name two main subsystems of vector scan VP machines.
Name two main subsystems of vector scan VP machines.
Which approach in photopolymerization does not require recoating of the resin layer?
Which approach in photopolymerization does not require recoating of the resin layer?
In the microelectronic industry, visible light is predominantly used for photomask materials.
In the microelectronic industry, visible light is predominantly used for photomask materials.
What device is used to pattern the large radiation beam in the mask projection approach?
What device is used to pattern the large radiation beam in the mask projection approach?
In photopolymerization processes, the _____ scan approach is typical of commercial SL machines.
In photopolymerization processes, the _____ scan approach is typical of commercial SL machines.
Match the photopolymerization approaches with their descriptions:
Match the photopolymerization approaches with their descriptions:
What type of light is primarily used in photopolymerization processes?
What type of light is primarily used in photopolymerization processes?
Charles Hull discovered solid polymer patterns by exposing UV curable materials to a scanning laser.
Charles Hull discovered solid polymer patterns by exposing UV curable materials to a scanning laser.
What is one common application of photo-curable resins in dentistry?
What is one common application of photo-curable resins in dentistry?
The mid 1980s marked the beginning of SL technology due to Charles Hull's experiments with _____ curable materials.
The mid 1980s marked the beginning of SL technology due to Charles Hull's experiments with _____ curable materials.
Match the following radiation types with their uses in curing commercial photopolymers:
Match the following radiation types with their uses in curing commercial photopolymers:
What is a significant drawback of vat photopolymerization technology?
What is a significant drawback of vat photopolymerization technology?
The surface finish of SL parts can range from submicron to over 100 um Ra depending on the orientation of the surfaces.
The surface finish of SL parts can range from submicron to over 100 um Ra depending on the orientation of the surfaces.
What is the maximum size of fabrication structure achievable with the specified microsterolithography process?
What is the maximum size of fabrication structure achievable with the specified microsterolithography process?
The minimum size of a hardened polymer unit in the microsterolithography process is _____ in the x and y directions.
The minimum size of a hardened polymer unit in the microsterolithography process is _____ in the x and y directions.
Match the advantages of vat photopolymerization technology with their descriptions:
Match the advantages of vat photopolymerization technology with their descriptions:
Which of the following statements about mask projection VP technologies is true?
Which of the following statements about mask projection VP technologies is true?
Photopolymers used in additive manufacturing are known for their exceptional impact strength and durability.
Photopolymers used in additive manufacturing are known for their exceptional impact strength and durability.
What is the position accuracy achieved in the x-y directions during the microsterolithography process?
What is the position accuracy achieved in the x-y directions during the microsterolithography process?
When laser light is focused on a particular area for a long time, then that particular area alone will be heated.
When laser light is focused on a particular area for a long time, then that particular area alone will be heated.
Laser technology is well suited for integration into modern systems like CAD and CAM?
Laser technology is well suited for integration into modern systems like CAD and CAM?
Electromagnetic waves that are applied in mobile phones are called:
Electromagnetic waves that are applied in mobile phones are called:
Purposes of laser material processing are based on the interaction of lasers with solid materials.
Purposes of laser material processing are based on the interaction of lasers with solid materials.
The relation between the wavelength λ and frequency is:
The relation between the wavelength λ and frequency is:
All the radiation in electromagnetic waves have the same wavelength.
All the radiation in electromagnetic waves have the same wavelength.
What is the full form of LASER and the acronym stands for?
What is the full form of LASER and the acronym stands for?
The smallest particle (quantum) in light is called _____ .
The smallest particle (quantum) in light is called _____ .
Study Notes
Additive Manufacturing
- Converting a CAD model to STL format simplifies the model's geometry for Additive Manufacturing (AM).
- The conversion to STL format is not a manual process and does not require user intervention.
- Medical modeling is an application area of AM that does not involve conventional CAD modeling.
- The eight steps in the AM process include conceptualization and CAD, conversion to STL, transfer and manipulation of STL file, machine setup, build, part removal and cleanup, post-processing of part, and application.
- Common considerations in design for AM include part orientation and removal of supports.
- Energy density is an important factor in metal AM systems.
- Visualization tools are used to check the part before building.
- Part removal and cleanup ensures the final product is ready for use and free of excess material.
- AM machines do not all run a variety of materials with numerous setup parameters.
- Repositioning the part before building allows it to be built at a specific location within the machine.
- Parts may require shrinkage or coating allowances.
- Segmentation of STL files divides parts for easier handling.
- Machine setup configures parameters for operation.
- Manual finishing prepares parts for final use.
- The process switches to computer-controlled building during the layer-based manufacturing phase.
- All AM machines alert the user when the build is complete or when there is no source material remaining.
- Significant manual finishing typically entails cleaning and preparing parts for ready-to-use condition.
- Support structures stabilize the part during the building process.
- Post-processing tasks do not always require the use of power tools.
- Common post-processing techniques include abrasive finishing, polishing, sandpapering, and application of coatings.
- AM materials often have small voids trapped inside them, leading to potential failure under stress.
- Poor technique in support removal can lead to low-quality output of the part.
- Anisotropic properties refer to different properties in different directions.
- Material degradation refers to material not bonding or crystallizing optimally.
- Support removal often requires manual skill to avoid damaging parts.
- Application specificity varies by the requirements of the final product.
- Parts produced by AM may behave differently than those made by conventional methods due to voids, anisotropic properties, or material degradation.
- The nominal layer thickness range for most SL technology machines is 0.05 - 0.1 mm.
- Thicker layers in AM do not lead to parts being built more precisely.
- Heat resistance or melting temperature must be considered during post-processing that involves heat.
- Powder-based systems do not require supports.
Photopolymer-Based Systems
- Photopolymer-based systems rely on light to cure liquid resin.
- Photopolymer-based systems require support from the same material used for the part.
- Photopolymer-based systems offer good accuracy with thin layers.
- Newer resins in photopolymer systems offer improved temperature resistance and strength.
- FDM Dimension machines typically have a nominal layer thickness of 0.254 mm.
Molten Material Systems
- Molten material systems extrude melted materials layer by layer.
- Extrusion processes like FDM do not always generate supports automatically.
- Cleaning parts produced by lamination methods is a laborious process due to waste material removal.
- Materials should be kept away from moisture and excessive light during handling.
Laser Systems
- The smallest particle in light is called a photon.
- The full form of LASER is Light Amplification by Stimulated Emission of Radiations.
- Laser material processing is based on the interaction of lasers with solid materials.
- The relationship between wavelength and frequency is inversely proportional.
- Electromagnetic waves have different wavelengths.
- Charles Hull discovered solid polymer patterns by exposing UV curable materials to a scanning laser.
Vat Photopolymerization
- Vat photopolymerization processes can be found in Stereolithography (SL).
- Two-Photon Vat Photopolymerization has both advantages and drawbacks.
- Photo Initiator System is a key component of Photopolymer chemistries.
- Photopolymerization Process Modeling is used to model irradiance and exposure in Vat Photopolymerization.
- Di-functional and higher functionality monomers are commonly used in SL resins.
- Vector Scan VP machines have two main subsystems: laser and optics systems, control system.
- The Two-photon approach does not require recoating of the resin layer.
- Visible light is not predominantly used for photomask materials in the microelectronic industry.
- A Digital Micromirror Device is used to pattern the large radiation beam in the mask projection approach.
- The vector scan approach is typical of commercial SL machines.
- Ultraviolet (UV) light is primarily used in photopolymerization processes.
- Epoxy and vinylether are not examples of free radical polymerization.
- A photoinitiator converts physical energy of light into chemical energy in the form of reactive intermediates.
- Photopolymer resins must be cleaned, post-cured, and finished after building.
- The recoating system is responsible for liquid resin application in laser scan VP machines.
- The Layer-wise approach in photopolymerization requires recoating of the resin layer.
Microstereolithography
- The maximum size of a fabrication structure achievable with the microsterolithography process is 10mm x 10mm x 10mm.
- The minimum size of a hardened polymer unit in the microsterolithography process is 5 µm x 5 µm in the x and y directions.
- The position accuracy achieved in the x-y directions during the microsterolithography process is 0.25 µm.
Design Considerations for Additive Manufacturing
- It is important to consider part orientation and removal of supports in design for AM.
- AM machines should be kept away from dirty or noisy environments.
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Description
Explore the essential steps and considerations in Additive Manufacturing (AM), including the conversion process to STL format and applications in medical modeling. Understand the importance of energy density and the role of visualization tools in the AM workflow for achieving high-quality parts.
