Additive Manufacturing Technologies Overview

Podcast

Play an AI-generated podcast conversation about this lesson

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?

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

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

True Signup and view all the answers

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

Direct Laser Sintering 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.

True Signup and view all the answers

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

True Signup and view all the answers

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

False Signup and view all the answers

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

Liquid-phase sintering Signup and view all the answers

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

False Signup and view all the answers

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

Layer compaction Signup and view all the answers

What technology is primarily used in binder printing?

Inkjet printing Signup and view all the answers

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

False Signup and view all the answers

It refers to the visible layering in FDM printed parts.

The visible step-like appearance on the surface of the part Signup and view all the answers

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

Lower accuracy than other AM processes Signup and view all the answers

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.

Studying That Suits You

Use AI to generate personalized quizzes and flashcards to suit your learning preferences.

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.