112 Questions
Where did the idea of layers in rapid prototyping and layer manufacture originate from?
Mapping Contour plot
Who was the first to apply the idea of contour plots to data?
Léon Lalanne
What is the significance of the 1874 map of Paris by L.L.Vauthier?
First statistical use of a contour map
Which system, proposed in 1956, has features similar to current stereolithography techniques?
Munz's patent system
What was the main contribution of Vauthier's map of Paris in 1892?
Generalizing the idea to three-way data
Who is credited with constructing the first contour plot?
Léon Lalanne
When did 3D CAD first appear according to the text?
1985
What did 3D CAD allow in the 1990s according to the text?
Automatic generation of instruction for automated manufacturing systems
What was one of the first commercial layered manufacturing systems enabled by 3D CAD in 1985 according to the text?
Stereo-Lithography Apparatus (SLA)
What technology allowed SLA to become slightly later and cheaper after Chuck Hull's design according to the text?
Fused deposition systems
What is a characteristic of some 'Upside down' SLA systems mentioned in the text?
"Wavy" liquid surface for laser to not be distorted by
What milestone has been reached today in terms of the number of 2D and 3D CAD models according to the text?
Over 10 billion 2D and 3D CAD models estimated to exist
What technology combined with 3D printing to enable a new phase in its growth?
CAD
In the past, how were most drawings produced?
With pencil or ink on paper
What did CAD fundamentally change according to the text?
The way we visualize 3D
What was the pivotal development period for new systems between 1985-1990?
ALM Commercial AM Development
How did making minor changes to drawings differ before the era of CAD?
Changes were manual and time-consuming
Which technology was NOT mentioned as part of the first additive system that combined to create 3D data?
CAD
What is the main difference between additive manufacturing and subtractive processes?
Additive processes add material to create shapes, while subtractive processes remove material.
What is a key advantage of additive manufacturing in terms of cost?
The cost does not increase with the complexity of the object being made.
What does the lecturer mention as one of the limits of any technology, including additive manufacturing?
Limits in the ability to design
Which term is NOT used as a synonym for additive manufacturing in the lecture?
Subtractive Manufacturing
What aspect makes additive manufacturing not 'quite free' according to the lecture?
There are always limits to any technology
What is mentioned as a downside regarding the cost in additive manufacturing?
The cost does not decrease with mass production
Who was among the first to invent a single-beam laser curing approach for layered manufacturing?
Doctor Hideo Kodama
In what year did Alain Le Mhaut, Olivier de Witte, and Jean Claude Andr file their patent for the stereolithography process?
1984
What was the reason behind the abandonment of the French inventors' application for the stereolithography process patent?
Lack of business perspective
Who defined the basic logic of an Additive layer system's operation through a patent?
Charles Hull
What did DiMatteo recognize in 1974 about stacking techniques in layer manufacturing?
Potential to produce hard-to-make surfaces
What is the Glass Transition Temperature (Tg) in polymers?
The temperature at which the polymer changes from brittle to soft/tough
What state of a polymer is characterized by it being brittle?
Glassy state
Why do amorphous polymers like ABS have a wider melt processing window compared to crystalline materials like Nylons?
Because amorphous polymers do not exhibit a Melt Temperature (Tm)
What happens if the filament is printed too cold?
It will not soften enough
In which state does a polymer exhibit softness and/or toughness?
Rubbery or Viscoelastic state
What is the significance of the Melt Temperature (Tm) in polymers?
It marks the transition temperature from soft/tough to a molten state
What is the primary difference between Selective Laser Sintering (SLS) and Selective Laser Melting (SLM)?
The type of material used in the process
In the context of Sheet Lamination, what role does the 'paper bulk additive layer' play?
To add strength to the final part
What is a key factor influencing the surface finish in Selective Laser Melting (SLM)?
The energy put into the powder based on beam diameter and speed
What challenges arise in creating small features like holes using high power in additive manufacturing processes?
Difficulty in defining the walls of small features
Why is it complex to achieve precise details when looking closely at Selective Laser Sintering (SLS) parts?
Insufficient merging between layers
What is a significant feature of Powder Bed Fusion processes like SLS and SLM?
They can produce complex geometries with high accuracy
What technology is used in Z-Corporation's printer to print fine patterns of glue onto a smooth bed of plaster powder?
Binder jetting
Which system mentioned in the text uses a different powder-based approach where a binder compound is deposited on each layer of powder?
Material jetting
What is a notable advantage of the AM process that Z-Corporation's printer uses?
Fast production speeds
Which method allows for the creation of full-color models with little postprocessing according to the text?
Material jetting
Which category of ALM systems involves the use of wire arc additive manufacturing?
Component & Binder 3D Printing & Gluing
What is a major limitation mentioned for Z-Corporation's printer in the text?
Requires specialized personnel to operate
What type of material is LAYWOO-D3, a 3D printing filament invented by Kai Parthy?
Wood-based composite
Why is it mentioned that the FDM filament cannot cross itself in a given layer?
To prevent high spots in the layer
Who are the inventors of the fused deposition modeling (FDM) technology?
Scott & Lisa Crump
What is the key parameter that determines the success of the FDM process according to the text?
Nozzle temperature
What is the main reason mentioned in the text for a bad outcome in FDM due to cooling?
Warping of the print
What does understanding the process window for a CNC machine tool help determine according to the text?
The key limitations of the manufacturing process
What metals are currently available for Direct Metal Deposition (DMD) processes?
Stainless Steel, Tool Steel, and Titanium
What is the main function of the powerful laser in Direct Metal Deposition (DMD) systems?
To trace the perimeter of a part
What type of materials can be fabricated using Direct Metal Deposition (DMD)?
Any shape and any material mix
What is one of the key parameters used for benchmarking in Additive Manufacturing?
Economic Feasibility
What technology enables the creation of full-color models with little post-processing according to the lecture?
Material Jetting Systems
What kind of diagrams are used for Additive Layer Manufacturing (ALM) processes according to the text?
Herring Bone Diagrams
What factor makes additive manufacturing an alternative to conventional machining for complex metallic parts?
When the 'buy to fly ratio' of a structure is above 30%
In additive manufacturing technologies, what does the 'buy to fly ratio' refer to?
The percentage of material that needs to be machined away in a structure
Which factor can be used to estimate the energy required for FDM technology based on the provided formula?
Amount of energy in Joules
What does the specific heat of the extruded material impact in FDM technology?
Energy requirement
What is a significant characteristic of ABS filament relevant to its use in FDM technology?
High density of 1.38 g/cm^3
What aspect of a part is assessed by examining the 'Thin Wall 1-3' benchmark in the SLS benchmark?
Strength and warping
In the SLS benchmark, what does the 'Rounded Corner' shape specifically evaluate?
Surface finish on overhanging sections
Why does the benchmark shape need to reflect typical build volumes and accuracy ranges of systems being compared?
To challenge most systems with small features
What does the 'Cylinder 1-4' assessment in the SLS benchmark focus on?
Resolution and accuracy
Which aspect of a part is primarily evaluated by looking at the 'Sharp Corners' in the SLS benchmark?
Accuracy of corners
Why are benchmarks built in multiple orientations according to the text?
To ensure challenges across various build orientations
How much energy is required for Selective Laser Melting (SLM)?
4.6kW
What is the volume of material per second needed for the extrusion process?
5.3mm3
What is the mass of material per second for the extrusion process?
0.007314g
What is the temperature change (T) during the extrusion process?
110oC
What is the specific heat capacity (c) used in the extrusion calculations?
1.3J/gK
How long does the build process take in seconds?
5400 seconds
Which company invented the STL file format in 1987?
3D Systems
What does CAD stand for in the context of the STL format?
Computer-Aided Design
What is the purpose of translating CAD models into STL before building on ALM systems?
To utilize the universal language of Manufacturing and Design
What characteristic is mentioned about the STL file format?
It has remained unchanged since its creation in 1987
What determines the quality of parts in relation to shape-only formats like STL?
Mesh density
What was the main reason behind the widespread adoption of STL as a general CAD exchange format?
'Lowest common denominator' for compatibility
What can help in printing longer bridges according to the text?
Cooling the print using a direct stream of air
What dictates the size and effect of the associated strains in RP processes?
Geometry of the components
In 3D printing, what feature size limit should be considered to avoid problems?
Accuracy beyond technology's capabilities
Which parameter determines the maximum size of a component in ALM systems?
Additive layer system's capability
What is defined as the absolute value of the deviation of the fabricated surface from the desired surface?
Surface roughness
Why does vertical build direction produce the best quality hole according to the text?
Affects the roundness of profiles positively
Why is shielding necessary when using certain materials like titanium in metal 3D printing?
To create an inert atmosphere for the right building conditions
What is the main limitation imposed by using an inert gas chamber in metal 3D printing?
Limits the size of parts that can be produced
What was the main idea behind Dr. Adrian Bowyer's RepRap movement and 'Crazy Fringe' in ALM?
Reducing costs and pushing boundaries
What did Dr. Adrian Bowyer's team aim to create primarily using plastic in additive layer manufacturing?
A machine that self-replicated and existed symbiotically with people
What problem does residual stress in metal 3D printing often lead to?
Deformation in a component
How did the Replicating Rapid Prototyper Project envisioned by Dr. Adrian Bowyer differ from reality?
It remained a dream project
What is the primary issue that large structures assembled from smaller parts to overcome build volume limitations face?
Excessive volume leading to surface ripples
In ALM processes, outcomes are highly dependent on which of the following factors?
Raw material quality and process parameters
Which manufacturing method results in models requiring labor-intensive finishing steps that can be as time-consuming as the initial manufacture?
All ALM methods equally
What makes post processing in ALM expensive and labor-intensive?
It is done entirely by hand
Which finishing step in ALM can be as long as the actual manufacturing process due to its time-consuming nature?
Post processing
What is a significant challenge faced by ALM systems despite overcoming build volume limitations?
Inconsistent heat distribution
How does Wire Arc Additive Manufacturing work?
By melting metal wire using an electric arc and extruding it layer by layer
What metals can Wire Arc Additive Manufacturing (WAAM) work with?
Stainless steel, nickel-based alloys, titanium alloys, and aluminium alloys
What is a challenge associated with Wire Arc Additive Manufacturing?
Heat management
Why is Wire Arc Additive Manufacturing (WAAM) not fully commercialized yet?
Because no commercially available system exists yet
What is one of the limitations mentioned for Wire Arc Additive Manufacturing?
High cost associated with the process
Which companies are mentioned as collaborators working on the development of Wire Arc Additive Manufacturing?
Kuka Systems, Airbus Defence and Space, FMC Technologies
What is a key difference between generative design and topological optimization?
Generative design requires artificial intelligence implementation.
What is a notable benefit achieved through the optimized design of a gearbox housing using ALM from a titanium alloy?
83% reduction in weight.
Why is there significantly less uncertainty regarding the parts' composition and behavior under load when using generative design?
The human sets the required parameters for the computer to iteratively design.
What technology combination disrupted established ways of doing things according to the provided text?
High Speed Internet + Cloud Computing
What is a distinctive feature of generative design in terms of design exploration?
Allows a comparison of a wide variety of possibilities.
What significant outcome results from implementing generative design in a gearbox housing's optimization process?
$1000 cost reduction
Study Notes
- Rapid prototyping and layer manufacture were attributed to Charles Hull, but the concept had been emerging for some time before he combined existing technologies in the first SLA systems.
- The idea of using layers in manufacturing was inspired by contour maps in geography, with the first statistical contour map published in 1843 by Léon Lalanne showing temperature variations.
- CAD (Computer-Aided Design) originated from engineering drawings around 100 years ago, with 2D CAD appearing in the 1980s and 3D CAD becoming more accessible in the 1990s for automated manufacturing systems.
- The concept of layered manufacturing dates back to 1974 when DiMatteo recognized the potential of stacking techniques for producing complex surfaces.
- The first additive manufacturing system in the 1980s combined material science, CNC movement control, and 3D data to lay the foundation for modern AM technologies.
- The evolution of ALM (Additive Layered Manufacturing) saw the development of various techniques like Vat photopolymerization, sheet lamination, powder bed fusion (SLS), selective laser sintering/melting, and binder jetting.
- ALM taxonomy categorizes seven generic categories of AM systems, with Vat photopolymerization being one of the earliest techniques that later led to alternative SLA-based systems with improved accuracy and cost-effectiveness.
- The development of ALM systems between 1985-1990 was driven by a combination of technological advancements, including the integration of material science, CNC control, and 3D data, leading to the commercialization of SLA systems and other AM technologies.
Explore the concepts covered in the first part of the lecture on Additive Manufacturing (AM), also known as Additive Layered Manufacturing, Rapid Prototyping, and 3D Printing. Learn about the introduction to AM, its benefits, and the historical development of layered manufacturing.
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