Additive Manufacturing Process Chain
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Questions and Answers

Which of the following is a key step in the Generalized AM Process Chain?

  • Exporting to PDF format
  • Network analysis
  • Market research
  • Post-processing of the part (correct)

    • Design for AM includes considerations like part orientation and the inclusion of undercuts.

    True

    What does STL stand for in additive manufacturing?

    STereoLithography

    The first step in the additive manufacturing process chain is __________.

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

    Match the following types of additive manufacturing systems with their description:

    <p>Photopolymer based systems = Use light to cure liquid resin into hardened plastic Powder-based systems = Use layers of powder material to create parts Molten material systems = Melt material to form 3D objects layer by layer Solid sheets = Lay down sheets of material and cut or bond them together</p> Signup and view all the answers

    What process is used after converting a CAD model to an STL file?

    <p>Transferring the STL file to the AM machine</p> Signup and view all the answers

    Metal systems in additive manufacturing typically do not use substrates.

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

    Name one application area of additive manufacturing that does not involve conventional CAD modeling.

    <p>Medical modeling</p> Signup and view all the answers

    What is a common requirement for some additive manufacturing (AM) processes during production?

    <p>Support structures to prevent collapse</p> Signup and view all the answers

    Post-processing is not typically a manual stage of finishing parts for application purposes.

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

    Name one potential issue with parts produced through additive manufacturing when it comes to material properties.

    <p>Trapped voids or bubbles</p> Signup and view all the answers

    Some AM processes may cause the material to degrade during the _____ stage.

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

    Match the following stages of AM with their descriptions:

    <p>Support removal = Initial part finishing stage Post-processing = Manual stages of part finishing Application = Parts ready for use Cleanup = Separation from build platform</p> Signup and view all the answers

    Which of the following is a true statement about the properties of parts produced by AM?

    <p>They may have anisotropic properties.</p> Signup and view all the answers

    The need for careful handling of parts during post-processing is not important for achieving good precision and finish.

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

    AM materials and processes are __________ all the time.

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

    What future trend is expected in additive manufacturing regarding material systems?

    <p>More common usage of color and multiple material systems</p> Signup and view all the answers

    Laser scanning technology is not used in reverse engineering data.

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

    What is the nominal layer thickness for most FDM Dimension machines?

    <p>0.254 mm</p> Signup and view all the answers

    What is a key advantage of using architectural modeling in design?

    <p>It allows modifications to show textures, colors, and shapes.</p> Signup and view all the answers

    Additive manufacturing may involve combining additive, subtractive, and even ______ handling phases.

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

    Post-processing involving heat does not require knowledge of the material properties involved.

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

    Match the following additive manufacturing technologies with their descriptions:

    <p>Laser scanning technology = Used for reverse engineering data Architectural modeling = Modifies designs for textures and colors STL file format = Commonly used but has limitations Hybrid technologies = Combines additive and subtractive processes</p> Signup and view all the answers

    What disadvantage do photopolymer-based systems have compared to other AM materials?

    <p>Poor mechanical properties</p> Signup and view all the answers

    The layer thickness for standard SL technology generally varies between _____ mm.

    <p>0.05 and 0.1</p> Signup and view all the answers

    Match the following AM processes with their characteristics:

    <p>Photopolymer-Based Systems = Good accuracy with thin layers but poor mechanical properties Powder-Based Systems = Does not require supports and uses a powder bed FDM Dimension = Uses a thicker nominal layer thickness Binder Printing = Allows parts to be colored with binders</p> Signup and view all the answers

    Which factor affects the choice of layer thickness in AM technologies?

    <p>Desired precision</p> Signup and view all the answers

    Newer resins in photopolymer systems can degrade rapidly without UV protective coatings.

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

    What advantage does a powder-based system have over photopolymer-based systems?

    <p>No need to use supports</p> Signup and view all the answers

    Which of the following is a requirement for molten material systems?

    <p>They require a support structure when melting and depositing materials.</p> Signup and view all the answers

    The Thermojet process eliminates the need for support structures in droplet-based systems.

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

    What is a significant challenge in cleaning up parts produced with lamination methods?

    <p>Processing the waste material for removal.</p> Signup and view all the answers

    Some machines using ______ technology need careful monitoring to operate effectively.

    <p>laser or printer</p> Signup and view all the answers

    Match the following application areas to their corresponding imaging techniques:

    <p>Medical modeling = X-ray imaging</p> Signup and view all the answers

    Which of the following factors is NOT worth considering for metal systems?

    <p>Maintenance of framework</p> Signup and view all the answers

    Part orientation is an important consideration in the design for additive manufacturing (AM).

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

    What is one method to improve recycling in additive manufacturing?

    <p>Using software to load materials offline.</p> Signup and view all the answers

    Study Notes

    Generalized AM Process Chain

    • Eight Step Process:
      • Conceptualization and CAD: Product ideas are conceptualized in a variety of forms, ranging from text descriptions to 3D CAD models.
      • Conversion to STL: The CAD model is converted to an STL (STereoLithography) file, which represents the geometry as a series of triangular facets.
      • Transfer to AM Machine and File Manipulation: The STL file is transferred to the AM machine, where it is manipulated and prepared for the build process. This involves separating the part from the build platform, adding support structures if necessary, and preparing the material for printing.
      • Build: The part is built layer by layer, using the specific additive manufacturing technology of the machine.
      • Part Removal and Cleanup: The part is removed from the build platform and any support structures are removed. Depending on the process and material, this can be a time-consuming and skilled process.
      • Post-Processing: The part is subjected to further finishing steps, such as sanding, polishing, or coating, to achieve the desired surface finish and properties. This step is highly application-specific.
      • Application: The finished part is ready for its intended use. However, it is important to note that AM parts may have different properties compared to traditionally manufactured parts, such as small voids or anisotropy (different properties in different directions).
      • Maintenance of Equipment: Regular maintenance of the AM machine is crucial to ensure proper operation and prevent damage. This includes monitoring delicate laser or printer technology, as well as cleaning and preventing exposure to dirt, electrical noise, or vibrations.
      • Material Handling Issues: AM materials, particularly powders and resins, can be sensitive to moisture and light. Proper handling is essential to maintain material quality and prevent degradation. Recycling of unused material is also an important consideration.
      • Design for AM:
        • Part Orientation: Proper orientation of the part on the build platform is crucial for effective support structure removal and minimal warping.
        • Removal of Supports: Designs that minimize the use of support structures, or employ easily removable supports.
        • Hollowing out Parts: Hollowing out parts can reduce weight, material consumption, and build time.
        • Inclusion of Undercuts and Other Manufacturing Constraints: Designing parts with undercuts, holes, or other difficult-to-manufacture features can be addressed by using specific AM processes or methods.
        • Interlocking Features: Designing parts with interlocking features can facilitate assembly and reduce the need for additional fasteners.
        • Reduction of Part Count in an Assembly: Designing complex parts as a single piece instead of multiple components can simplify the manufacturing process.
        • Identification Marking/Numbering: Integrating identifying markings or numbers directly into the design can enhance traceability and organization.

    Variations in AM Processes

    • Powder-Based Systems: These systems deposit a bed of powder layer by layer and use a binder or sintering process to fuse the material.
    • Photopolymer-Based Systems: These systems use photopolymerization to solidify liquid resins. This technology is generally accurate but can be fragile.
    • Molten Material Systems: These systems melt and deposit materials in a molten state. Different processes utilize distinct methods like droplet-based deposition or extrusion, each having advantages in terms of support structure creation and ease of use.
    • Solid Sheet Systems: These systems utilize layering of solid sheets, which are then cut and bonded together. This method eliminates the need for support structures but requires careful handling and post-processing of waste material.

    Metal Systems

    • Metal systems utilize similar principles as polymer systems and feature unique considerations:
      • Substrates: Metal parts often require a substrate to provide stability and support during printing.
      • Energy Density: Metal systems require high energy densities to melt and fuse the metal powder.
      • Weight: Metal parts are heavier than their polymer counterparts, which affects build times and stability.
      • Accuracy: Metal systems can achieve high levels of accuracy, but fine details might still be a challenge.
      • Speed: Metal printing is generally slower than polymer or ceramic printing.

    Application Areas

    • Medical Modeling: 3D models created from medical scans (CT, MRI, 3D Ultrasound) aid in diagnosis, planning, and surgical procedures.
    • Reverse Engineering Data: Laser scanning technology captures 3D data from existing objects for creating replicas or designing new parts.
    • Architectural Modeling: Architectural models created using AM can visualize designs, explore concepts, and showcase textures, colors, and shapes in a realistic manner.

    Future Considerations

    • Thicker Layers and Processing Regions: Advancements in AM processes are exploring the use of thicker layers and larger processing regions to increase speed and efficiency.
    • Beyond STL Files: The limitations of the STL file format for complex part designs may lead to the development of alternative formats for representing part information.
    • Multi-Material Systems: The use of multiple materials and colors within a single part will become more common, requiring advanced software and processes.
    • Hybrid Technologies: Integrating additive, subtractive, and robotic manufacturing techniques for further optimization and complexity.
    • Software Optimization: Specialized software will be developed to optimize AM processes and streamline design workflows.
    • Direct Digital Manufacturing: Increased adoption of AM will require standardized software processes and workflows for more seamless integration.

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    Additive Manufacturing Process Chain PDF

    Description

    Explore the eight-step process involved in additive manufacturing. From conceptualizing product ideas to the final part cleanup, this quiz covers crucial phases like CAD conversion and build techniques. Test your knowledge of how modern manufacturing transforms design to reality.

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