Generalized Additive Manufacturing Process Chain
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Questions and Answers

What is one common action required before building a part?

  • Verify the part is correct (correct)
  • Change the color of the part
  • Use the machine to build automatically
  • Add additional parts without checking

Unusual cases may require segmentation of STL files.

True (A)

What type of tools are available for STL file manipulation?

Software tools for purchase or free download

In the AM process, parts may require ______ or coating allowances.

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

What happens if an incorrect setup procedure is followed in an AM machine?

<p>The final quality may be unacceptable (A)</p> Signup and view all the answers

Match the following stages of the AM process with their descriptions:

<p>Setup = Specifying parameters unique to the machine Building = Switching from manual control to computer control Removal = Cleaning and finishing the built parts Verification = Confirming the part's correctness before building</p> Signup and view all the answers

All AM machines operate with the same number of setup parameters.

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

The AM procedure includes a ______ based manufacturing process.

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

What does STL stand for in the context of additive manufacturing?

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

The process of converting CAD models to STL files is manual in most CAD systems.

<p>False (B)</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 eight steps in the AM process chain include conceptualization and CAD, conversion to STL, transfer to AM machine, __________, build, part removal and cleanup, post-processing of part, and application.

<p>machine setup</p> Signup and view all the answers

Match the following AM machine types with their characteristics:

<p>Photopolymer based systems = Use liquid resins cured by light Powder-based systems = Utilize powdered materials that are melted or sintered Molten material systems = Extrude thermoplastic materials Solid sheets = Stack and bond layers of sheets</p> Signup and view all the answers

What is a key consideration in the design for additive manufacturing?

<p>Removal of supports (B)</p> Signup and view all the answers

Metal systems in additive manufacturing do not require consideration of weight and speed.

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

STL files approximate the surface of a CAD model with a series of __________.

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

What is often required during the removal of support structures in additive manufacturing (AM)?

<p>Significant manual work (B)</p> Signup and view all the answers

Post-processing stages in additive manufacturing require no manual work.

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

What are the typical finishing processes involved in post-processing?

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

Some AM machines need __________ structures to prevent part collapse during the building process.

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

Match the following terms to their descriptions:

<p>Post-processing = Finishing stages for application readiness Support structures = Prevent parts from collapsing during construction Anisotropic properties = Different material properties in different directions Voids = Small trapped bubbles that can cause part failure</p> Signup and view all the answers

Why do AM parts often not behave according to standard material specifications?

<p>AM creates materials with voids (B)</p> Signup and view all the answers

The number of applications for AM output is decreasing as technologies improve.

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

What can cause material degradation during the AM process?

<p>Poor bonding, lack of linking, or improper crystallization during the build.</p> Signup and view all the answers

What is the typical nominal layer thickness for most additive manufacturing machines?

<p>0.1 mm (C)</p> Signup and view all the answers

Thicker layers in additive manufacturing result in quicker builds but more precision.

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

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

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

In photopolymer-based systems, all liquid vat systems must use support from the same material as that used for the ______.

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

Match the following additive manufacturing system types with their characteristics:

<p>Photopolymer-Based Systems = Good accuracy with thin layers; requires support from similar material Powder-Based Systems = No need for supports; builds layer-by-layer from powder FDM Dimension Machines = Typical layer thickness of 0.254 mm Zcorp. Parts = Can be colored using colored binder material</p> Signup and view all the answers

What is one advantage of newer resins used in photopolymer systems?

<p>Improved strength and ductility (D)</p> Signup and view all the answers

Binder printing into a powder bed creates unique parts in additive manufacturing.

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

What common issue may arise with fine details in designs during additive manufacturing?

<p>Wall thickness problems</p> Signup and view all the answers

Which technology is commonly used for architectural modeling to enhance designs?

<p>Laser scanning technology (D)</p> Signup and view all the answers

The STL file format works well with all additive manufacturing processes.

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

What future trend is expected in additive manufacturing regarding materials?

<p>Increased use of color and multiple material systems.</p> Signup and view all the answers

The process of using a combination of additive and subtractive methods in manufacturing is known as ______.

<p>hybrid technology</p> Signup and view all the answers

Match the following components of additive manufacturing with their descriptions:

<p>Direct digital manufacturing = The process of creating objects from digital designs Post-processing techniques = Methods used to enhance the final appearance of 3D printed objects Figureprints = Specialized conversion software for game models Standardized software processes = Protocols developed for consistent AM processing</p> Signup and view all the answers

What process requires the generation of support structures for droplet-based systems?

<p>Thermojet process (B), Extrusion process (C)</p> Signup and view all the answers

Solid sheets in lamination methods do not require support structures.

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

Name one aspect that must be carefully monitored in certain 3D printing machines.

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

Exposure to ________ should be avoided during material handling.

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

Which of the following is NOT a consideration for Metal Systems compared to polymer systems?

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

Match the following application areas with their relevant technologies:

<p>Medical modeling = CT, MRI, 3D ultrasound Polymer systems = Bonding of polymer sheets Printing processes = Droplet and extrusion methods Material handling = Exposure prevention</p> Signup and view all the answers

What design considerations help with additive manufacturing processes?

<p>Part orientation, removal of supports, hollowing out parts</p> Signup and view all the answers

Machines should not be used in ________ or ________ environments to avoid malfunction.

<p>dirty, noisy</p> Signup and view all the answers

Flashcards

STL File

A file format used to represent a 3D model as a collection of triangles, commonly used in additive manufacturing. It describes the model's geometry without any information about material properties or colors.

Conceptualization

The initial stage of product development, involving the generation of ideas and concepts for a new product, often through sketches, descriptions, or 3D models.

CAD Model

A digital representation of a 3D object created using computer-aided design software, used to design and create various objects, from simple shapes to complex products.

Transfer to AM Machine

The process of sending a prepared STL file to an additive manufacturing machine to initiate the build process.

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Part Removal and Cleanup

The process after the build is complete, involving removing the part from the build platform (and supports, if used), cleaning excess material, and potentially removing build support structures.

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Machine Setup

The process of preparing the additive manufacturing machine for a build, including loading material, setting build parameters (temperature, speed, etc.), and calibrating the machine.

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Post-Processing

The stage after a part is built and removed, that involves treatments like smoothing surfaces, painting, or heat treating to enhance the final product's properties or appearance.

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Application

The intended use or purpose of the 3D printed part, often determined by the design and material choice.

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Part Verification

Ensuring the STL file accurately represents the desired part before building.

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Visualization Tool

Software that allows viewing and manipulating 3D models, such as STL files, for better understanding and planning.

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Part Repositioning

Adjusting the part's position and orientation within the build chamber for optimal printing.

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Multiple Part Building

The ability to build multiple copies of the same part or different parts in a single build session.

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Shrinkage and Coating Allowances

Adjustments made to the STL file to account for material shrinkage or coating thickness during the build process.

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STL File Segmentation

Dividing a complex STL file into smaller segments for easier and more efficient printing.

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Machine Setup Parameters

Specific settings on the AM machine that influence build quality, such as material type, layer thickness, and build platform dimensions.

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Semi-Automated Build

The early stages of the AM build process that involve manual control, interaction, and decision-making.

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Support Structures

Structures added during 3D printing to prevent parts from collapsing or warping during the build process.

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Support Removal

The process of carefully removing support structures from a 3D printed part after it's finished.

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Anisotropic Properties

Materials with different properties in different directions, often a result of 3D printing processes.

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Voids or Bubbles

Small air pockets trapped inside 3D printed parts, potentially causing weakness or failure.

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Material Degradation

A weakening or change in material properties during the 3D printing process.

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Application of AM Parts

Using 3D printed parts for their intended purposes, often with unique material properties.

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Expanding Applications

The increasing use of 3D printed parts in various industries due to continuous improvements in materials and technologies.

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Reverse Engineering

The process of taking an existing physical object and recreating its design using digital tools, like laser scanning, to understand its structure and function.

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Laser Scanning

A technology used in reverse engineering to create a detailed 3D model of an object by measuring its shape using a laser beam.

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Architectural Modeling

Creating virtual 3D models of buildings or other structures, often incorporating textures, colors, and shapes to present a realistic visual representation.

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AM Processing Optimization

Improving the efficiency and quality of additive manufacturing processes using advanced software. Specific examples include software for converting designs for 3D printing and post-processing techniques.

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Direct Digital Manufacturing

A manufacturing approach where designs are directly transferred to production machines, eliminating traditional tooling and prototyping.

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Layer Thickness

The vertical dimension of each layer in an AM build. Thicker layers create faster prints but may impact accuracy.

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Fine Details in AM

Small features like thin walls or intricate curves that may be challenging to build accurately with some AM technologies.

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Material Variation in AM

Different materials will affect the time, resources, and skill needed to build and post-process a part.

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Support Structures in Photopolymer

Liquid photopolymer AM (like vat polymerization) often relies on supports made of the same material as the part.

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Support Material in Droplet Deposition

In droplet deposition AM, support material can be modified as it comes out of the print head, making it easier to remove.

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Advantages of Photopolymer AM

Photopolymer processes offer good accuracy with thin layers, but parts typically have weaker mechanical properties.

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Powder-Based AM Support Structures

Powder-based AM (like SLS) typically doesn't need support structures. The powder itself supports the part.

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Colored Binder Printing

Zcorp. parts created using binder jetting technology can be colored by using different colored binder materials.

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Study Notes

Generalized Additive Manufacturing Process Chain

  • The process chain involves several key stages
  • Key steps include conceptualization and CAD, STL conversion, file transfer, machine setup, building, part removal, cleanup, post-processing, and application
  • Variations exist between different AM machines related to photopolymer, powder-based, and molten material systems, and solid sheets
  • Variations can be observed in substrate choice, energy density, weight, accuracy, and speed during the manufacturing process
  • Maintenance of equipment and material handling are essential considerations, and design for AM (part orientation, support removal, hollowing out parts, undercuts, etc.) plays a crucial part
  • There are specified applications that do not involve conventional CAD modeling. These include medical modeling, reverse engineering data, and architectural modeling.

Eight Steps in AM

  • Conceptualization and CAD: Idea generation, product visualization (textual & narrative, sketches, or 3D CAD)
  • Conversion to STL: Sterolithography-derived, describes CAD model using triangular facets. Automated in most CAD systems
  • Transfer to AM Machine & STL File Manipulation: Transferring STL file, verification, repositioning, and manipulation for building
  • Machine Setup: Setup parameters specific to the machine, options for material and layer thickness variation
  • Build: Semi-automated initial stages, followed by computer control, layer creation, and platform adjustments, until completion or material exhaustion
  • Removal and Cleanup: Separating the part from the build platform and excess material, supporting structures removal, possible manual intervention.
  • Post-processing: Finishing for application purposes (abrasive finishing, coatings), application specific, and possible need for power tools and auxiliary equipment (polishing tubs, ovens)
  • Application: Post-processing, material behavior considerations, and the constant increase of applications for AM processes

Variations from One AM Machine to Another

  • Photopolymer-Based Systems: Easy setup, potential support modification, accuracy, and limited mechanical properties
  • Powder-Based Systems: No support needed, layer-by-layer deposition, achievable coloring
  • Molten Material Systems: Support structure generation varies based on the process, e.g. automatic or user-generated
  • Solid Sheets: No support needed, waste material management critical, and method-specific considerations in the final part appearance
  • Metal Systems: Considerations for subtractive manufacturing, energy density, weight, accuracy, and speed

Additional Notes

  • Other factors, like quality control (QC) and post-processing methods, are important to the overall process.
  • The provided information also discusses different material handling procedures, specific design considerations for the application and various technologies used in the process of Additive Manufacturing.
  • The list includes exercises for the students to conduct further research and develop a better overview of the process

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Additive Manufacturing Process Chain PDF

Description

Explore the essential stages of the Generalized Additive Manufacturing (AM) process chain. This quiz covers key phases such as conceptualization, CAD, and variations across different AM techniques. Understand the importance of design for AM and the role of maintenance in manufacturing equipment.

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