Additive Manufacturing Process Chain
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Questions and Answers

Which technology is utilized for reverse engineering data?

  • 3D printing
  • Virtual reality
  • Computer-aided design
  • Laser scanning technology (correct)

    • Architectural modeling designs only depict the exact productions of the final design.

    False

    What is becoming more common in additive manufacturing processes?

    Color and multiple material systems

    Standardized software processes are needed as direct digital manufacturing becomes more ______.

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

    Match the following types of manufacturing processes with their descriptions:

    <p>Additive manufacturing = Building up material layer by layer Subtractive manufacturing = Removing material from a solid block Hybrid manufacturing = Combination of additive and subtractive processes Direct digital manufacturing = Creating physical products directly from digital files</p> Signup and view all the answers

    What is the first step in the Generalized AM Process Chain?

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

    The STL format describes the CAD model in terms of color and texture.

    <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

    The process of converting a CAD model to STL involves approximating the surface of the model with a series of __________.

    <p>triangular facets</p> Signup and view all the answers

    Match the following types of AM machines with their characteristics:

    <p>Photopolymer based systems = Use liquid resin cured by light Powder-based systems = Utilize powdered materials for printing Molten material systems = Extrude heated materials to create objects Solid sheets = Layer materials that are cut then bonded</p> Signup and view all the answers

    What type of file is created from the conversion of a CAD model?

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

    Energy density is a factor to consider in metal additive manufacturing.

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

    List two design considerations for additive manufacturing.

    <p>Part orientation, Removal of supports</p> Signup and view all the answers

    What is one action required prior to building the part?

    <p>Verify the part is correct</p> Signup and view all the answers

    All AM machines require the same setup parameters regardless of the material used.

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

    What may be necessary for some parts before they are built?

    <p>Shrinkage or coating allowances</p> Signup and view all the answers

    The first few stages of the building process are ________.

    <p>semi-automated</p> Signup and view all the answers

    Match the actions with their descriptions:

    <p>Verify the part is correct = Ensures specifications are met Machine setup = Adjusting specific parameters based on material Build phase = Layer-based manufacturing process Removal and cleanup = Preparing the part for final use</p> Signup and view all the answers

    What can happen if an incorrect setup procedure is followed?

    <p>The part will be built with unacceptable quality</p> Signup and view all the answers

    All AM machines will alert the user when the build is complete or when there is no material remaining.

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

    What might some unusual cases require concerning STL files?

    <p>Segmentation of STL files</p> Signup and view all the answers

    Which of the following processes automatically generates support structures?

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

    Solid sheets used in lamination methods require support structures during processing.

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

    What is one common issue experienced by paper-based systems?

    <p>Handling problems</p> Signup and view all the answers

    Part orientation, removal of supports, and hollowing out parts are all considerations for __________.

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

    Match the following issues with their relevant considerations:

    <p>Laser technology = Fragility and monitoring Material exposure = Moisture and light Equipment maintenance = Clean environments Recycling material = Offline loading using software</p> Signup and view all the answers

    Which of the following factors is NOT a concern for metal systems compared to polymer systems?

    <p>Support structure</p> Signup and view all the answers

    Interlocking features are considered an advanced design element in conventional CAD modeling.

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

    Name one application area for medical modeling that does not involve conventional CAD.

    <p>CT or MRI</p> Signup and view all the answers

    Why do some additive manufacturing machines require support structures?

    <p>To prevent parts from collapsing or warping</p> Signup and view all the answers

    Post-processing is an automatic stage that requires no manual effort.

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

    What may happen to parts created through additive manufacturing under mechanical stress?

    <p>They may fail due to small voids or bubbles trapped inside them.</p> Signup and view all the answers

    In additive manufacturing, the initial part of the __________ stage is the cleanup stage.

    <p>post-processing</p> Signup and view all the answers

    Match the terms related to additive manufacturing with their definitions:

    <p>Void = An empty space within the material that can cause structural weakness Post-processing = The stage involving finishing and refining parts after production Anisotropic = Material properties that vary in different directions Support structures = Temporary frameworks that prevent part warping during production</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 potential downside of parts made via additive manufacturing compared to traditional methods?

    <p>They may not behave according to standard material specifications</p> Signup and view all the answers

    Manual skill is unnecessary for the support removal stage in additive manufacturing.

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

    Thicker layers in additive manufacturing lead to more precise parts.

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

    What are some post-processing tasks that can benefit from the use of power tools?

    <p>Abrasive finishing, polishing, or application of coatings.</p> Signup and view all the answers

    What must be considered during post-processing that involves heat in additive manufacturing?

    <p>Heat resistance or melting temperature of the material.</p> Signup and view all the answers

    In powder-based systems, a bed of powder is deposited __________.

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

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

    <p>Photopolymer-Based Systems = Use support from the same material as the part Powder-Based Systems = No need to use supports Binder Printing = Can create colored parts FDM Dimension = Has a nominal layer thickness of 0.254 mm</p> Signup and view all the answers

    What is a disadvantage of photopolymer-based systems?

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

    Newer resins in photopolymer-based systems degrade rapidly without proper UV protection.

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

    What material processing category can affect the time and resources required in additive manufacturing?

    <p>Use of different materials.</p> Signup and view all the answers

    Which of the following is NOT a process discussed in vat photopolymerization?

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

    Photopolymerization reaction rates are independent of the irradiance and exposure time.

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

    What is the purpose of using photo initiators in photopolymerization?

    <p>To initiate the polymerization reaction upon exposure to light.</p> Signup and view all the answers

    The __________ pattern is one of the scan patterns used in vector scan VP machines.

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

    Match the following components with their functions in vat photopolymerization:

    <p>Monomer formulations = Building the polymer structure Photospeed = Rate of reaction based on exposure Laser-resin interaction = Curing the resin with laser Interpenetrating polymer network = Enhanced mechanical properties</p> Signup and view all the answers

    Which configuration is used in Photopolymerization Processes that irradiates entire layers at one time?

    <p>Mask projection</p> Signup and view all the answers

    Visible light is predominantly used in the microelectronic industry.

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

    What is a primary benefit of the two-photon approach in photopolymerization?

    <p>Recoat is unnecessary as the part is fabricated below the resin surface.</p> Signup and view all the answers

    In the __________ scan approach, scanning laser beams are needed.

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

    What type of radiation is primarily used in photopolymerization processes?

    <p>Ultraviolet (UV) radiation</p> Signup and view all the answers

    Match the following photopolymerization configurations with their characteristics:

    <p>Vector scan = Point-wise approach with recoating required Mask projection = Layer-wise approach with large radiation beam Two-photon = High resolution with no recoating needed Resin application = Reapplication of resin for each new layer</p> Signup and view all the answers

    Photopolymers were developed in the 1980s.

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

    Who is credited with the discovery of producing solid polymer patterns through UV curing in the mid-1980s?

    <p>Charles Hull</p> Signup and view all the answers

    Photo-curable resins are often used in __________ to seal deep grooves in teeth.

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

    Match the following types of radiation with their applications in curing photopolymers:

    <p>Gamma rays = Curing of photopolymers for coatings X-rays = Medical imaging and treatment UV radiation = 3D printing processes Visible light = Some photopolymerization systems</p> Signup and view all the answers

    What is one of the primary advantages of vat photopolymerization technology?

    <p>High accuracy and surface finish</p> Signup and view all the answers

    Current stereolithography materials possess high impact strength and durability compared to injection molded thermoplastics.

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

    What is the minimum size of a hardened polymer unit produced in microfabrication applications?

    <p>5 µm x 5 µm x 3 µm</p> Signup and view all the answers

    The accuracy of the SLA-250 is __________.

    <p>0.002 in/in</p> Signup and view all the answers

    Match the following characteristics with their corresponding technologies:

    <p>Mask Projection VP = Speed advantage over laser scan SL Two-Photon VP = Used primarily for high-resolution microfabrication SLA-250 = Precision of 0.002 in/in Microsterolithography = 5-µm spot size of the UV beam</p> Signup and view all the answers

    Which of the following is a drawback of using photopolymers in additive manufacturing?

    <p>Ageing leading to degraded mechanical properties</p> Signup and view all the answers

    Mask projection technologies are less efficient than laser scanning for SLA processes.

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

    What constrains the chemistry of commercially used photopolymers?

    <p>Acrylates and epoxies</p> Signup and view all the answers

    Which types of radiation are most commonly used to cure commercial photopolymers?

    <p>UV and electron beams</p> Signup and view all the answers

    Photopolymers are primarily used as photoresists in the biomedical field.

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

    What is the role of a photoinitiator in photopolymer chemistry?

    <p>To convert physical energy of light into chemical energy.</p> Signup and view all the answers

    In laser scan vat photopolymerization, a UV laser selectively solidifies a liquid photopolymer resin to create __________.

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

    Match the following types of polymerization with their respective materials:

    <p>Free radical polymerization = Acrylate Cationic polymerization = Epoxy Vinylether polymerization = Vinylether Both types = Acrylate and Epoxy</p> Signup and view all the answers

    What is the purpose of the recoater blade in the vector scan vat photopolymerization process?

    <p>It smooths the surface of the vat and deposits new resin.</p> Signup and view all the answers

    Acrylates polymerize through a radical mechanism, while epoxides polymerize through a cationic mechanism.

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

    What is the term for the network formation that occurs when acrylates and epoxides polymerize?

    <p>Interpenetrating polymer network formation</p> Signup and view all the answers

    Study Notes

    Generalized Additive Manufacturing Process Chain

    • Additive manufacturing (AM) is a process chain with several steps
    • Key steps include conceptualization and CAD, conversion to STL, transfer to AM machine, machine setup, build, part removal, cleanup, and post-processing
    • The process sequence can vary from one AM machine to another, requiring different setup parameters and potentially different materials or layer thicknesses

    Variations from One AM Machine to Another

    • Different AM machines have varying layer thicknesses, potentially impacting build precision
    • Factors like droplet size, laser diameter, or extrusion head influence detail in the build
    • Material properties (e.g., heat resistance, melting point) and post-processing requirements can vary significantly between machines
    • Methods (e.g., powder-based, molten material, or photopolymer; droplet deposition, or extrusion) create unique advantages and disadvantages in terms of support structures, build speed, material handling, cleanup
    • Some AM machines require support structures that may need to be removed manually, potentially impacting the quality of the finished part
    • Not all AM processes are based on layers, certain techniques may involve different approaches
    • Photopolymer systems are generally more accurate with thin layers but have poorer mechanical properties
    • Powder-based systems often don't need support structures
    • Molten material systems often use support structures and require different post-processing techniques
    • Solid sheet systems require different processes for managing leftover material and require careful considerations about part orientation
    • Metal systems need to take into account energy density, weight, and accuracy during the design process

    Maintenance of Equipment

    • Some machines use vulnerable laser or printer technology that need careful monitoring (e.g., noise or vibration)
    • Material handling procedures should consider moisture and light exposure to avoid damage
    • Some machines recycle the material from a build that didn't form correctly
    • Different materials may require specific pre and post process considerations, like using of temperature controlled environment

    Design for AM

    • Part orientation is crucial for successful builds
    • Support structures for parts are often necessary, but removing them can be complex
    • Complex features (e.g., undercuts, interlocking features) may be involved
    • Overall part count reduction can enhance efficiency
    • Designing for AM may involve additional consideration of support structures, part orientation, varying layer thickness and different material properties to ensure successful parts and minimal waste

    Application Areas

    • AM can be used in areas outside conventional CAD modeling, like medical modeling (using CT, MRI, 3D ultrasound data), reverse engineering (using laser scanning), and architectural modeling
    • AM processes are often unique and have to be considered in design, and the use of the process can vary by machine type
    • AM processes increasingly involve not just one material, but combinations of different materials

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    Related Documents

    Additive Manufacturing Process Chain PDF
    Vat Photopolymerization Processes PDF

    Description

    Explore the essential steps involved in the additive manufacturing process chain, from conceptualization to post-processing. Understand how variations in AM machines and their unique properties can affect the quality and precision of builds. Learn about equipment maintenance and material handling for optimal performance.

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