Week 1: Additive Manufacturing Principles and Applications
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Questions and Answers

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.

    False

    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 __________.

    <p>Rapid Prototyping</p> Signup and view all the answers

    Match the following additive manufacturing processes with their descriptions:

    <p>Binder Jetting = A liquid binding agent is deposited to join powder materials Material Extrusion = Material is selectively dispensed through a nozzle Vat Photopolymerization = Liquid photopolymer is selectively cured by light Directed Energy Deposition = Focused thermal energy fuses materials during deposition</p> Signup and view all the answers

    What is a primary feature of Additive Manufacturing (AM)?

    <p>Parts are built layer by layer from a CAD file</p> Signup and view all the answers

    Pre-processing and post-processing are often the most considered aspects of the AM production process.

    <p>False</p> Signup and view all the answers

    What is one critical factor to consider before buying an additive manufacturing system?

    <p>Cost of cleaning materials</p> Signup and view all the answers

    Additive Manufacturing eliminates the need for __________.

    <p>tooling</p> Signup and view all the answers

    Match the following steps in the AM process chain:

    <p>Create 3D CAD model = File Preparation Orient parts = Build Set-up Remove supports = Post-processing Slice part horizontally = Build stage</p> Signup and view all the answers

    Which of the following components is NOT part of the generic process chain?

    <p>Transport completed part</p> Signup and view all the answers

    What is an essential consideration during the design stage of AM?

    <p>Manufacturing process restrictions</p> Signup and view all the answers

    What percentage of the module grade does the group coursework contribute?

    <p>60%</p> Signup and view all the answers

    Additive Manufacturing is a process where material is removed to create parts.

    <p>False</p> Signup and view all the answers

    List one type of conventional manufacturing method described in the content.

    <p>Subtractive or Formative</p> Signup and view all the answers

    Additive Manufacturing builds parts layer by layer from a ____ file.

    <p>CAD</p> Signup and view all the answers

    Match the following assessment components with their respective percentages of the module grade:

    <p>Group coursework = 60% Written examination = 40%</p> Signup and view all the answers

    Which method applies mechanical forces to material to mold it?

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

    Students are encouraged to speak up during sessions if they have questions or concerns.

    <p>True</p> Signup and view all the answers

    Who should students contact for queries related to polymer Additive Manufacturing?

    <p>Candice Majewski</p> Signup and view all the answers

    The written examination format is described as ____ book and online.

    <p>open</p> Signup and view all the answers

    What is a characteristic of Additive Manufacturing?

    <p>Layers are built from a digital file</p> Signup and view all the answers

    What is a common requirement for processes involving overhanging geometries in 3D printing?

    <p>Support structures are often necessary</p> Signup and view all the answers

    Self-supporting powdered-polymer systems do not require any support structures.

    <p>True</p> Signup and view all the answers

    What is one major reason for the necessity of support structures in 3D printing?

    <p>Steep inclines</p> Signup and view all the answers

    The process of preparing build material can range from snapping a ready-made cartridge into place to ______.

    <p>sieving/mixing/shovelling powder</p> Signup and view all the answers

    Match the following post-processing steps with their descriptions:

    <p>Cool-down procedure = Removal of parts before they are fully cooled can cause warpage Post-curing = Further UV curing is required for certain parts Removal from base-plate = Some parts are built directly onto a solid foundation Painting/colouring = Applying aesthetic finishes to 3D printed parts</p> Signup and view all the answers

    Which of the following is NOT a consideration during machine set-up?

    <p>Post-cooling temperature</p> Signup and view all the answers

    Selection of layer thickness does not influence the mechanical properties of the final product.

    <p>False</p> Signup and view all the answers

    What is one of the roles of support structures during 3D printing?

    <p>To provide stability for overhanging geometries</p> Signup and view all the answers

    Certain processes build directly onto a ______.

    <p>solid base</p> Signup and view all the answers

    What is a potential consequence of removing parts before they have properly cooled in High Speed Sintering?

    <p>Warpage of the parts</p> Signup and view all the answers

    What does a lower tolerance in STL file creation usually imply?

    <p>Higher accuracy</p> Signup and view all the answers

    It is not necessary to check an STL file for errors before submission.

    <p>False</p> Signup and view all the answers

    What software is commonly used to check and repair STL files?

    <p>Magics</p> Signup and view all the answers

    The file size of an STL file is directly related to the number of ________.

    <p>triangles</p> Signup and view all the answers

    Match the following STL file resolutions with the corresponding number of triangles:

    <p>0.1 mm = 224 triangles 0.01 mm = 2400 triangles 0.001 mm = 24648 triangles</p> Signup and view all the answers

    Which of the following effects can orientation have on a 3D printed model?

    <p>Surface finish</p> Signup and view all the answers

    Using only automatic fixing functions is the best approach for repairing STL files.

    <p>False</p> Signup and view all the answers

    What characteristics does orientation affect in a 3D print?

    <p>Surface finish, mechanical properties, and build height</p> Signup and view all the answers

    The tolerance specified during the creation of an STL file should be based on the requirements of the ________.

    <p>part</p> Signup and view all the answers

    What is a primary benefit of using conformal channels in manufacturing?

    <p>Increase rate of heating/cooling</p> Signup and view all the answers

    Functionally graded materials allow for control of properties in specific areas.

    <p>True</p> Signup and view all the answers

    Identify one limitation of using additive manufacturing.

    <p>Geometrical accuracy</p> Signup and view all the answers

    Tool mass reduction increases effective thermal __________ of a tool.

    <p>diffusivity</p> Signup and view all the answers

    Match the following terms with their descriptions:

    <p>Hybrid tooling = Combines different manufacturing technologies Post-finishing = Required for achieving desired surface quality Thermal conductivity = Ability to conduct heat Material choice = Critical factor influencing manufacturing success</p> Signup and view all the answers

    What is the primary factor that affects the file size of an STL file?

    <p>Number of triangles</p> Signup and view all the answers

    It is sufficient to rely solely on automatic methods for fixing issues in an STL file.

    <p>False</p> Signup and view all the answers

    What software is mentioned as commonly used for checking and repairing STL files?

    <p>Magics</p> Signup and view all the answers

    A lower tolerance specified during the creation of an STL file generally implies __________ accuracy.

    <p>higher</p> Signup and view all the answers

    Match the following resolutions with their corresponding number of triangles:

    <p>0.1 mm = 224 triangles 0.01 mm = 2400 triangles 0.001 mm = 24648 triangles</p> Signup and view all the answers

    Which aspect of the 3D printing process can orientation impact?

    <p>Build height</p> Signup and view all the answers

    Errors in an STL file can potentially __________ an entire build.

    <p>crash</p> Signup and view all the answers

    What is one of the main benefits of rapid prototyping?

    <p>Reduced costs and lead times</p> Signup and view all the answers

    Direct rapid tooling involves producing a master or pattern from which the tool is made.

    <p>False</p> Signup and view all the answers

    What is one common method of rapid tooling mentioned in the content?

    <p>Silicon rubber moulding</p> Signup and view all the answers

    Rapid prototyping allows for _____ number of design iterations, resulting in better quality parts.

    <p>higher</p> Signup and view all the answers

    Match the following benefits with their descriptions:

    <p>Reduced costs = Lower financial investment Quicker time to market = Faster product availability Increased design iterations = More opportunities for design improvements Less design restrictions = Greater design flexibility</p> Signup and view all the answers

    Which of the following describes indirect rapid tooling?

    <p>Producing a master or pattern for tool production</p> Signup and view all the answers

    One disadvantage of conventional tooling is shorter lead times compared to rapid tooling.

    <p>False</p> Signup and view all the answers

    Name one primary benefit of direct rapid tooling.

    <p>Higher geometrical complexity</p> Signup and view all the answers

    One concern when transitioning from prototyping to production is ensuring we can produce parts in _____ production.

    <p>series</p> Signup and view all the answers

    Which of the following is a potential drawback of rapid tooling?

    <p>Challenges in scaling up for mass production</p> Signup and view all the answers

    What is the primary purpose of support structures in 3D printing?

    <p>To support overhanging geometries</p> Signup and view all the answers

    Powdered-polymer systems require separate support materials for overhangs.

    <p>False</p> Signup and view all the answers

    What is one critical step in the machine set-up process for additive manufacturing?

    <p>File preparation</p> Signup and view all the answers

    In High Speed Sintering, removing parts before they have properly cooled can lead to __________.

    <p>warpage</p> Signup and view all the answers

    What might influence the selection of layer thickness in additive manufacturing?

    <p>Mechanical properties and surface finish</p> Signup and view all the answers

    Warm-up procedures are not necessary in polymer Laser Sintering.

    <p>False</p> Signup and view all the answers

    What is one advantage of using automated software for nesting in additive manufacturing?

    <p>Increased efficiency</p> Signup and view all the answers

    During build material preparation, operations may range from sieving to ________.

    <p>mixing</p> Signup and view all the answers

    What percentage of the module grade is attributed to the written examination?

    <p>40%</p> Signup and view all the answers

    Additive Manufacturing involves removing material to create parts.

    <p>False</p> Signup and view all the answers

    What file is essential for the additive manufacturing process?

    <p>CAD file</p> Signup and view all the answers

    In conventional manufacturing, material is often removed from a solid block using __________.

    <p>subtractive processes</p> Signup and view all the answers

    Match the following roles with their corresponding responsibilities:

    <p>Candice Majewski = Queries related to polymer additive manufacturing Kamran Mumtaz = Queries related to metal additive manufacturing Discussion sessions = Opportunities for student feedback Group coursework = Contributes 60% of the module grade</p> Signup and view all the answers

    What is a key benefit of using Additive Manufacturing compared to conventional manufacturing?

    <p>It allows for complex geometries that were previously difficult to achieve.</p> Signup and view all the answers

    Students are encouraged to engage during feedback sessions.

    <p>True</p> Signup and view all the answers

    What type of approach does Additive Manufacturing utilize to build parts?

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

    The process of creating parts in Additive Manufacturing is done __________ from a digital file.

    <p>layer by layer</p> Signup and view all the answers

    Which of these aspects is NOT typically a focus during the module’s assessment?

    <p>Online quizzes</p> Signup and view all the answers

    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. 
    • 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.

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