Podcast
Questions and Answers
Which of the following terms is another name for Additive Manufacturing?
Which of the following terms is another name for Additive Manufacturing?
- Thermal Fusion
- Subtractive Manufacturing
- Digital Manufacturing (correct)
- Mass Production
Powder bed fusion is a process that involves the use of a binder to join powder materials.
Powder bed fusion is a process that involves the use of a binder to join powder materials.
False (B)
List one factor that affects the choice of an additive manufacturing process.
List one factor that affects the choice of an additive manufacturing process.
Accuracy required
The process of creating a likeness of a part using layer-manufacturing is known as __________.
The process of creating a likeness of a part using layer-manufacturing is known as __________.
Match the following additive manufacturing processes with their descriptions:
Match the following additive manufacturing processes with their descriptions:
What is a primary feature of Additive Manufacturing (AM)?
What is a primary feature of Additive Manufacturing (AM)?
Pre-processing and post-processing are often the most considered aspects of the AM production process.
Pre-processing and post-processing are often the most considered aspects of the AM production process.
What is one critical factor to consider before buying an additive manufacturing system?
What is one critical factor to consider before buying an additive manufacturing system?
Additive Manufacturing eliminates the need for __________.
Additive Manufacturing eliminates the need for __________.
Match the following steps in the AM process chain:
Match the following steps in the AM process chain:
Which of the following components is NOT part of the generic process chain?
Which of the following components is NOT part of the generic process chain?
What is an essential consideration during the design stage of AM?
What is an essential consideration during the design stage of AM?
What percentage of the module grade does the group coursework contribute?
What percentage of the module grade does the group coursework contribute?
Additive Manufacturing is a process where material is removed to create parts.
Additive Manufacturing is a process where material is removed to create parts.
List one type of conventional manufacturing method described in the content.
List one type of conventional manufacturing method described in the content.
Additive Manufacturing builds parts layer by layer from a ____ file.
Additive Manufacturing builds parts layer by layer from a ____ file.
Match the following assessment components with their respective percentages of the module grade:
Match the following assessment components with their respective percentages of the module grade:
Which method applies mechanical forces to material to mold it?
Which method applies mechanical forces to material to mold it?
Students are encouraged to speak up during sessions if they have questions or concerns.
Students are encouraged to speak up during sessions if they have questions or concerns.
Who should students contact for queries related to polymer Additive Manufacturing?
Who should students contact for queries related to polymer Additive Manufacturing?
The written examination format is described as ____ book and online.
The written examination format is described as ____ book and online.
What is a characteristic of Additive Manufacturing?
What is a characteristic of Additive Manufacturing?
What is a common requirement for processes involving overhanging geometries in 3D printing?
What is a common requirement for processes involving overhanging geometries in 3D printing?
Self-supporting powdered-polymer systems do not require any support structures.
Self-supporting powdered-polymer systems do not require any support structures.
What is one major reason for the necessity of support structures in 3D printing?
What is one major reason for the necessity of support structures in 3D printing?
The process of preparing build material can range from snapping a ready-made cartridge into place to ______.
The process of preparing build material can range from snapping a ready-made cartridge into place to ______.
Match the following post-processing steps with their descriptions:
Match the following post-processing steps with their descriptions:
Which of the following is NOT a consideration during machine set-up?
Which of the following is NOT a consideration during machine set-up?
Selection of layer thickness does not influence the mechanical properties of the final product.
Selection of layer thickness does not influence the mechanical properties of the final product.
What is one of the roles of support structures during 3D printing?
What is one of the roles of support structures during 3D printing?
Certain processes build directly onto a ______.
Certain processes build directly onto a ______.
What is a potential consequence of removing parts before they have properly cooled in High Speed Sintering?
What is a potential consequence of removing parts before they have properly cooled in High Speed Sintering?
What does a lower tolerance in STL file creation usually imply?
What does a lower tolerance in STL file creation usually imply?
It is not necessary to check an STL file for errors before submission.
It is not necessary to check an STL file for errors before submission.
What software is commonly used to check and repair STL files?
What software is commonly used to check and repair STL files?
The file size of an STL file is directly related to the number of ________.
The file size of an STL file is directly related to the number of ________.
Match the following STL file resolutions with the corresponding number of triangles:
Match the following STL file resolutions with the corresponding number of triangles:
Which of the following effects can orientation have on a 3D printed model?
Which of the following effects can orientation have on a 3D printed model?
Using only automatic fixing functions is the best approach for repairing STL files.
Using only automatic fixing functions is the best approach for repairing STL files.
What characteristics does orientation affect in a 3D print?
What characteristics does orientation affect in a 3D print?
The tolerance specified during the creation of an STL file should be based on the requirements of the ________.
The tolerance specified during the creation of an STL file should be based on the requirements of the ________.
What is a primary benefit of using conformal channels in manufacturing?
What is a primary benefit of using conformal channels in manufacturing?
Functionally graded materials allow for control of properties in specific areas.
Functionally graded materials allow for control of properties in specific areas.
Identify one limitation of using additive manufacturing.
Identify one limitation of using additive manufacturing.
Tool mass reduction increases effective thermal __________ of a tool.
Tool mass reduction increases effective thermal __________ of a tool.
Match the following terms with their descriptions:
Match the following terms with their descriptions:
What is the primary factor that affects the file size of an STL file?
What is the primary factor that affects the file size of an STL file?
It is sufficient to rely solely on automatic methods for fixing issues in an STL file.
It is sufficient to rely solely on automatic methods for fixing issues in an STL file.
What software is mentioned as commonly used for checking and repairing STL files?
What software is mentioned as commonly used for checking and repairing STL files?
A lower tolerance specified during the creation of an STL file generally implies __________ accuracy.
A lower tolerance specified during the creation of an STL file generally implies __________ accuracy.
Match the following resolutions with their corresponding number of triangles:
Match the following resolutions with their corresponding number of triangles:
Which aspect of the 3D printing process can orientation impact?
Which aspect of the 3D printing process can orientation impact?
Errors in an STL file can potentially __________ an entire build.
Errors in an STL file can potentially __________ an entire build.
What is one of the main benefits of rapid prototyping?
What is one of the main benefits of rapid prototyping?
Direct rapid tooling involves producing a master or pattern from which the tool is made.
Direct rapid tooling involves producing a master or pattern from which the tool is made.
What is one common method of rapid tooling mentioned in the content?
What is one common method of rapid tooling mentioned in the content?
Rapid prototyping allows for _____ number of design iterations, resulting in better quality parts.
Rapid prototyping allows for _____ number of design iterations, resulting in better quality parts.
Match the following benefits with their descriptions:
Match the following benefits with their descriptions:
Which of the following describes indirect rapid tooling?
Which of the following describes indirect rapid tooling?
One disadvantage of conventional tooling is shorter lead times compared to rapid tooling.
One disadvantage of conventional tooling is shorter lead times compared to rapid tooling.
Name one primary benefit of direct rapid tooling.
Name one primary benefit of direct rapid tooling.
One concern when transitioning from prototyping to production is ensuring we can produce parts in _____ production.
One concern when transitioning from prototyping to production is ensuring we can produce parts in _____ production.
Which of the following is a potential drawback of rapid tooling?
Which of the following is a potential drawback of rapid tooling?
What is the primary purpose of support structures in 3D printing?
What is the primary purpose of support structures in 3D printing?
Powdered-polymer systems require separate support materials for overhangs.
Powdered-polymer systems require separate support materials for overhangs.
What is one critical step in the machine set-up process for additive manufacturing?
What is one critical step in the machine set-up process for additive manufacturing?
In High Speed Sintering, removing parts before they have properly cooled can lead to __________.
In High Speed Sintering, removing parts before they have properly cooled can lead to __________.
What might influence the selection of layer thickness in additive manufacturing?
What might influence the selection of layer thickness in additive manufacturing?
Warm-up procedures are not necessary in polymer Laser Sintering.
Warm-up procedures are not necessary in polymer Laser Sintering.
What is one advantage of using automated software for nesting in additive manufacturing?
What is one advantage of using automated software for nesting in additive manufacturing?
During build material preparation, operations may range from sieving to ________.
During build material preparation, operations may range from sieving to ________.
What percentage of the module grade is attributed to the written examination?
What percentage of the module grade is attributed to the written examination?
Additive Manufacturing involves removing material to create parts.
Additive Manufacturing involves removing material to create parts.
What file is essential for the additive manufacturing process?
What file is essential for the additive manufacturing process?
In conventional manufacturing, material is often removed from a solid block using __________.
In conventional manufacturing, material is often removed from a solid block using __________.
Match the following roles with their corresponding responsibilities:
Match the following roles with their corresponding responsibilities:
What is a key benefit of using Additive Manufacturing compared to conventional manufacturing?
What is a key benefit of using Additive Manufacturing compared to conventional manufacturing?
Students are encouraged to engage during feedback sessions.
Students are encouraged to engage during feedback sessions.
What type of approach does Additive Manufacturing utilize to build parts?
What type of approach does Additive Manufacturing utilize to build parts?
The process of creating parts in Additive Manufacturing is done __________ from a digital file.
The process of creating parts in Additive Manufacturing is done __________ from a digital file.
Which of these aspects is NOT typically a focus during the module’s assessment?
Which of these aspects is NOT typically a focus during the module’s assessment?
Flashcards
What is Additive Manufacturing?
What is Additive Manufacturing?
Additive Manufacturing (AM) is a process where parts are built layer by layer, directly from a 3D CAD model.
What is a key advantage of Additive Manufacturing?
What is a key advantage of Additive Manufacturing?
AM eliminates the need for traditional tooling, which can be time-consuming and expensive to create.
What is pre-processing in AM?
What is pre-processing in AM?
Pre-processing refers to the steps taken before the actual build process in AM, to ensure a successful and efficient build.
What is post-processing in AM?
What is post-processing in AM?
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Why is design so important in AM?
Why is design so important in AM?
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Why are pre-processing activities important?
Why are pre-processing activities important?
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What should anyone considering AM understand?
What should anyone considering AM understand?
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STL Tolerance
STL Tolerance
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STL Triangle Count
STL Triangle Count
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STL File Checking
STL File Checking
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3D Print Orientation
3D Print Orientation
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3D Print Nesting
3D Print Nesting
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Surface Finish
Surface Finish
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Mechanical Properties
Mechanical Properties
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Build Height
Build Height
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3D Print Assembly
3D Print Assembly
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Nesting in 3D Printing
Nesting in 3D Printing
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Support Structures
Support Structures
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Build Material Preparation
Build Material Preparation
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Levelling Build Material
Levelling Build Material
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Post-Processing
Post-Processing
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Orientation Specification
Orientation Specification
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Minimum Distance Between Parts
Minimum Distance Between Parts
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Layer Thickness
Layer Thickness
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Slicing in 3D Printing
Slicing in 3D Printing
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Laser Sintering
Laser Sintering
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Types of Additive Manufacturing Processes
Types of Additive Manufacturing Processes
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What is Rapid Prototyping?
What is Rapid Prototyping?
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What is Rapid Tooling?
What is Rapid Tooling?
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Factors affecting AM process selection
Factors affecting AM process selection
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What are subtractive manufacturing methods?
What are subtractive manufacturing methods?
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What are formative manufacturing methods?
What are formative manufacturing methods?
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What is a CAD file?
What is a CAD file?
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What is powder bed fusion in AM?
What is powder bed fusion in AM?
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What is vat polymerization in AM?
What is vat polymerization in AM?
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What is fused deposition modeling (FDM) in AM?
What is fused deposition modeling (FDM) in AM?
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What is direct energy deposition (DED) in AM?
What is direct energy deposition (DED) in AM?
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Study Notes
Additive Manufacturing Principles and Applications
- Additive manufacturing (AM) is a process where parts are built layer by layer directly from a CAD file.
- AM eliminates the need for tooling.
- AM has a wide range of processing methods and materials.
- Pre-processing and post-processing are often overlooked but critically important for a successful build.
- Pre-processing and post-processing can add time and cost and can even cause catastrophic failures if not considered.
- If purchasing an AM system, understand the material, equipment, and space requirements.
- AM involves a process chain:
- File preparation (.stl creation, checking, repair)
- Build setup (orienting parts, support generation, slicing)
- Physical build process (layer by layer build)
- Support removal
- Post-processing (e.g., cleaning, curing, surface finishing).
File Preparation
- Most AM systems use .stl file format for Stereolithography.
- Original format for Sterolithography.
- .stl files can lose accuracy during processing.
- .stl files only store surface geometry.
- Other CAD file information like layers or colors are lost.
- File sizes are directly related to the number of triangles used to approximate the 3D model.
- Tolerances are specified during the creation of the .stl file, and some loss of accuracy occurs during conversion.
- Check for errors in .stl format before submission to avoid build failures.
- Use software like 'Magics' from Materialise to check and repair errors in .stl files.
Orientation and Nesting
- Orientation can impact a part's:
- Surface finish
- Mechanical properties
- Build time
- In some cases, certain orientations are better for specific processes. Parts should be orientated for optimal accuracy and build time.
- Processes may work better in certain orientations.Â
- It's crucial to consider the build orientation for better quality of the finished part.
- Nesting considers the arrangement of multiple components to maximize space utilization in a single build.
- Many machine-specific programs for orientation and nesting may not be user-friendly.
- Machine orientation can influence build height (and therefore build time).
- Nesting can be manual.
- Some software solutions automate the nesting process.
- The nesting software should allow users to specify part orientations and spacing.
Support Structures
- Most AM processes need support structures for overhanging features to deal with gravity.
- Support structures are separate weaker components.
- Depending on the material and process features, parts may not support themselves, requiring support structures during build.
- Support structures can affect the accuracy of the part and can add to build time.
- Some materials or processes make support structures entirely unnecessary.
- Common support structure reasons include steep inclines, overhangs, or internal 'islands'.
- Correct removal of supports is critical to the quality of the final part.
- Some processes may require post-removal of supports.
Machine Setup
- Machine setup is process-specific and involves factors like:
- File preparation
- Build material preparation (e.g., warming up specialized materials)
- Build material placement
- Build area preparation (levelling)
- Process-dependent software controls operations like slicing.
- In some cases, extra steps are necessary to prepare the build materials.
Post-Processing
- Post-processing procedures are critical, depending on the process used.
- Procedures include cooling, curing, support removal, painting, or infiltration.
- The process needs to be controlled to avoid warpage in the final part.
- Removal and cleaning of excess material can be critical to final part quality.
- Processing, including curing, can significantly alter the part's properties, so the post-processing is important.
- Post-processing depends on the process being used.
Surface Finishing
- Surface finishing procedures like bead blasting, machining, polishing, or chemical treatments are crucial to achieve the desired surface qualities.
- Surface needs can include smoothing, roughening, or specific characteristics.
- Finishing decisions are made based on factors like material, accuracy, and restrictions.
Process Selection
- Not all processes are suitable for all applications
- Accuracy, mechanical properties, application, surface finishes, number of parts needed, size, and cost must be considered before deciding on a process.
Hybrid Tooling
- Often combinations of technologies are used for optimal solutions in a design.
- This could include AM for core and machining for surface finishing.
Additive Manufacturing for Direct Manufacture
- AM began as a form of rapid prototyping, but it has evolved into tools for direct manufacturing that are faster and less costly.
- Using AM as a design tool and a direct manufacturing process brings new benefits.
Benefits of Additive Manufacturing
- Design freedom
- Personalization
- Reduced costs and lead times (no tooling)
- Faster time to market
- Higher number of design iterations
- Reduced design restrictions
- Greater control of material properties
- Possibility of part consolidation and reducing the number of parts
- Faster delivery of replacement parts
- Localised manufacture (e.g., reduced transportation costs)
Limitations of Additive Manufacturing
- Materials
- Cost
- Range of available materials
- Integrity of parts
- Accuracy and tolerances (repeatability for properties)
- Surface finish
- Number of parts
- Size/complexity of parts
- System cost, build time, build area
- Specific software for certain processes
- Training requirements
- Keeping software current and compatible with new capabilities
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Description
This quiz explores the fundamental principles and applications of additive manufacturing (AM). It covers key processes, materials, and the importance of pre- and post-processing in successful builds. Additionally, it highlights the steps involved in AM, from file preparation to final touches.
