Additive Manufacturing Technologies Overview
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Questions and Answers

What does AM stand for?

Additive Manufacturing

What is the biggest limitation of AM technology at the moment?

The limited range of materials that can be used.

What is the 'functional graded material' used for?

It is used for applications that require materials to withstand high temperatures while maintaining a temperature gradient.

Why is the process of 'robocasting' important for ceramics?

<p>It is an ideal method for creating ceramic parts that can withstand high temperatures.</p> Signup and view all the answers

The use of lasers in AM technologies is more expensive than the use of electrons.

<p>True (A)</p> Signup and view all the answers

Which of the following is NOT a common approach to metal part creation in powder bed fusion processes?

<p>Direct Laser Sintering (B)</p> Signup and view all the answers

In the SLS process, the powder bed is maintained at an elevated temperature that is just below the melting point.

<p>True (A)</p> Signup and view all the answers

In the FDM process, the extrusion head is typically vertically oriented.

<p>True (A)</p> Signup and view all the answers

Binder jetting is primarily used for the creation of metal parts.

<p>False (B)</p> Signup and view all the answers

Which of the following is NOT a common method to improve the surface quality of FDM parts?

<p>Liquid-phase sintering (D)</p> Signup and view all the answers

The use of 'whiskers' for reinforcement in AM has been growing in recent years.

<p>False (B)</p> Signup and view all the answers

What is the key process step for ensuring proper bonding and stability for powder bed fusion processes?

<p>Layer compaction</p> Signup and view all the answers

What technology is primarily used in binder printing?

<p>Inkjet printing</p> Signup and view all the answers

Binder jetting is generally more expensive than laser-based powder bed fusion processes.

<p>False (B)</p> Signup and view all the answers

It refers to the visible layering in FDM printed parts.

<p>The visible step-like appearance on the surface of the part (D)</p> Signup and view all the answers

Which of the following is considered a disadvantage of binder printing?

<p>Lower accuracy than other AM processes (A)</p> Signup and view all the answers

Flashcards

What is Additive Manufacturing (AM)?

A manufacturing process that builds objects layer by layer by adding material, as opposed to traditional methods that remove material.

What are the benefits of AM?

AM offers numerous advantages, including reduced material waste, increased design freedom, faster prototyping, and on-demand production.

What is a Voxel?

A 3D equivalent of a pixel, representing a single point of material in a 3D model.

What is Rapid Prototyping?

A process of quickly creating physical prototypes using AM technology for testing and evaluation.

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What is a Digital Twin?

A virtual representation of a physical object, used for design, analysis, and simulation.

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What is a Patent?

A legal document protecting an invention for a certain time period, giving the inventor exclusive rights to use, sell, and make it.

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What is Freeform Fabrication?

A manufacturing method that allows the creation of complex shapes without the need for molds.

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What is the difference between 3D Printing and AM?

3D Printing refers to a specific technology, while AM encompasses a broader range of technologies that involve adding material layer by layer.

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What is the STL file format?

A standard file format for 3D models used in AM machines.

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What is a CAD software?

Computer-Aided Design software that enables engineers and designers to create virtual 3D models.

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What is a Powder Bed Fusion (PBF) process?

An AM process that uses a heat source to fuse powder particles together, layer by layer.

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What is Selective Laser Sintering (SLS)?

A PBF process that uses a laser to selectively melt and fuse powder particles, forming a solid layer.

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What is Selective Laser Melting (SLM)?

A PBF process that uses a laser to completely melt powder particles, creating a dense and solid layer.

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What is Electron Beam Melting (EBM)?

A PBF process that uses an electron beam to melt and fuse powder particles, creating a solid layer.

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What is Vat Polymerization?

An AM process that uses a liquid photopolymer resin that solidifies when exposed to light.

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What is Stereolithography (SLA)?

An AM process that uses a laser to selectively solidify liquid photopolymer resin, layer by layer.

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What is Digital Light Processing (DLP)?

An AM process that uses a projector to project light patterns onto liquid photopolymer resin, solidifying layers simultaneously.

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What is Continuous Liquid Interface Production (CLIP)?

An AM process that uses oxygen and light to continuously solidify photopolymer resin, creating parts faster.

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What is a Photopolymer?

A material that changes its properties, usually hardening, when exposed to light.

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What is a Photoinitiator?

A chemical in photopolymer resins that initiates the polymerization process when exposed to light.

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What are Support Structures?

Temporary structures created during AM to support overhangs and complex shapes.

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What is Post-Processing?

Operations performed after AM to clean, finish, or improve the properties of the printed part.

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What is a Melt Pool?

The molten area of powder particles created by a laser or electron beam during PBF processes.

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What is Balling?

A phenomenon where molten material in a melt pool shrinks and forms spheres instead of a continuous track, leading to defects in the final part.

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What is Sputtering?

An effect caused by overheating in the melt pool, leading to expulsion of liquid droplets and unmelted particles.

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What is a Functional Graded Material?

A material that has a gradual change in properties from one side to the other, enhancing its performance.

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What is Mind Mapping?

A visual technique for brainstorming and organizing ideas by connecting related concepts.

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What is the LCA of a Product?

Life Cycle Assessment, which analyzes the environmental impact of a product throughout its entire lifecycle.

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What is a Disruptive Technology?

A technology that disrupts existing markets and industries, creating new opportunities and challenges.

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What is a Laser?

A device that emits a high-intensity beam of concentrated light.

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What is a Galvanometer?

A device that controls the direction of a laser beam by deflecting it using mirrors.

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What is a CNC Machine?

Computer Numerical Control machine that uses computer programs to control the movement of cutting tools for manufacturing.

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What is an Actuator?

A device that converts electrical or hydraulic signals into mechanical motion.

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What is a Sensor?

A device that detects and measures physical quantities, such as temperature, pressure, or light.

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What is the Importance of Material Properties in AM?

The choice of material is crucial for AM, as different materials have unique properties that affect the final part's performance.

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Why are ceramics used in AM?

Ceramics are used in AM because of their unique properties, such as high heat resistance, durability, and wear resistance.

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What are Sintering and Full Melting?

Sintering involves partially melting powder particles to bind them together, while full melting completely melts the powder for a solid part.

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Why are patents important in AM?

Patents protect inventions, allowing inventors to control the use of their technology, driving innovation and protecting intellectual property.

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Study Notes

Additive Manufacturing Technologies

  • Additive manufacturing (AM) is a set of technologies that create objects layer by layer, enabling the creation of complex shapes and structures impossible with traditional manufacturing methods.
  • AM has several variations based on the methods used to fuse materials, most significantly the type and form of the raw material.
  • AM processes vary in terms of cost, speed, and accuracy, creating different advantages and disadvantages for certain applications.
  • AM techniques are connected with creativity and design, with AM promoting innovative design solutions.
  • The initial designs are usually in a digital format (CAD) which is used to create the final product

AM Material Classifications

  • AM materials are categorized as liquid, particles (powder), molten materials, and sheets/laminates.
  • Liquid materials such as photopolymers are used in techniques like stereolithography (SLA).
  • Powder materials are used in powder bed fusion (PBF) processes such as selective laser melting (SLM) and selective laser sintering (SLS).
  • Molten materials (liquid materials) are used in material extrusion (ME) processes like fused deposition modeling (FDM).
  • Sheet materials/laminates are used in sheet lamination processes

Principles of Additive Manufacturing

  • AM's principle is to construct an object layer by layer using a digital 3D model for guidance.
  • The 3D model is converted into a series of 2D cross-sectional slices or layers.
  • Each layer is then built upon the previous one, layering material to create the final form of the object.
  • The raw material used in the process can vary across techniques but is always transformed via a specific process into the solid form in the layer.
  • Key steps in many types of AM comprise: the use of CAD design software, the transformation (and often refinement) of the data, transfer to the manufacturing device, the printing (layer by layer) and the (sometimes extensive) post-processing steps to remove supports and refine the object for its final application.

Advantages of AM

  • Reduced material waste as compared to traditional manufacturing methods.
  • Ability to produce complex shapes and geometries.
  • Improved design flexibility for rapid prototyping.
  • Allows for more creative and innovative designs.
  • Potentially lower costs for small batch production or customized products.
  • Increased customization options and shorter lead times, particularly relevant for specialized or niche products.

Disadvantages of AM

  • Higher initial investment costs for the equipment.
  • Limited material selection for certain technologies.
  • The potential for greater defects or inconsistencies in the printed object as compared to traditional methods.
  • Slower production rates than subtractive methods.
  • The potential for issues in repeatability and reproducibility of certain features from print to print.
  • Increased requirement for post-processing (e.g., finishing or surface treatment)

AM Process Examples and Specifics

  • Several AM processes use various methods to build the product, such as melting, sintering, deposition, or curing.
  • Stereolithography (SLA), Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), and Selective Laser Melting (SLM) are all common examples.
  • Each technology (e.g., SLA) comes with its own constraints and specifications regarding the types of materials usable.

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Description

Explore the world of additive manufacturing (AM) technologies that create objects layer by layer. This quiz covers various methods, material classifications, and the benefits of AM in innovative design. Test your understanding of AM and its applications in modern manufacturing.

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