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

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

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

    <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 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</p> Signup and view all the answers

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

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

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

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

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

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

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

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

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

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

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

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

    Solid sheets in lamination methods do not require support structures.

    <p>True</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</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

    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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    Related Documents

    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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