Generalized Additive Manufacturing Process Chain
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Questions and Answers

What is a primary focus of architectural modeling in reverse engineering data?

  • Modifying designs to display textures and colors (correct)
  • Using only the STL file format for designs
  • Eliminating layers in the printing process
  • Creating accurate replicas of existing structures

    • Color and multiple material systems will likely decrease in prevalence within additive manufacturing technologies in the future.

    False

    What is one potential advancement in additive manufacturing processes mentioned?

    The commercialization of hybrid technologies combining additive and subtractive processes.

    As direct digital manufacturing becomes more common, there will be a need to develop standardized software processes based around _______.

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

    Match the following technologies with their descriptions:

    <p>Laser scanning technology = Used for reverse engineering data STL file format = May not work well with some processes Hybrid technologies = Combine additive and subtractive processes Figureprints = Software for converting designs from World of Warcraft</p> Signup and view all the answers

    Which layer thickness is typical for most FDM Dimension machines?

    <p>0.254 mm</p> Signup and view all the answers

    Fine details in a design can be problematic for some AM technologies.

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

    What is a key advantage of using photopolymer-based systems?

    <p>Good accuracy with thin layers</p> Signup and view all the answers

    In powder-based systems, there is no need to use __________.

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

    Match the following systems with their characteristics:

    <p>Photopolymer-based systems = Require support material for parts FDM Dimension machines = Thicker layer for faster builds Zcorp parts = Colored using binder material Post-processing techniques = Depend on material properties</p> Signup and view all the answers

    Which of the following is NOT a characteristic of powder-based systems?

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

    What is often required during the support removal process in additive manufacturing?

    <p>Significant manual work and skill</p> Signup and view all the answers

    Newer resins in photopolymer systems do not degrade rapidly if UV protective coatings are applied.

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

    Additive manufacturing parts typically behave according to standard material specifications of conventional methods.

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

    What must be considered during post-processing that involves heat?

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

    What type of finishing may be involved in the post-processing stage of additive manufacturing?

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

    AM machines often create parts with small voids or _____ trapped inside them.

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

    What is a key characteristic of droplet-based systems like the Thermojet process?

    <p>They automatically generate supports.</p> Signup and view all the answers

    Match the following stages of additive manufacturing with their descriptions:

    <p>Cleanup = Initial part of post-processing involving removal of excess material Post-processing = Finishing parts for application purposes Support removal = Processes to prevent part warping during building Application = Final use of the parts in practical applications</p> Signup and view all the answers

    Solid sheets used in lamination methods eliminate the need for waste material processing.

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

    What is a common characteristic of materials produced through additive manufacturing?

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

    Which of the following is a common action required before building a part?

    <p>Verify the part is correct</p> Signup and view all the answers

    Which of the following is a key step in the generalized additive manufacturing (AM) process chain?

    <p>Post-processing of the part</p> Signup and view all the answers

    All AM machines require the same setup parameters.

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

    List two factors to consider when comparing metal systems to polymer systems.

    <p>Energy density and accuracy</p> Signup and view all the answers

    All applications of additive manufacturing require high performance components.

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

    What is typically required to prepare parts that need adjustments for material properties like shrinkage?

    <p>Shrinkage or coating allowances</p> Signup and view all the answers

    What can be used in post-processing to assist with tasks like polishing?

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

    The conversion to STL occurs automatically within most CAD systems.

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

    Equipment maintenance is crucial when using ____ or printer technology.

    <p>laser</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

    Match the following application areas with their corresponding technologies:

    <p>Computerized Tomography = Medical modeling Magnetic Resonance Imaging = Medical imaging 3D Ultrasound = Diagnostic imaging CAD modeling = Conventional design practices</p> Signup and view all the answers

    The process of building a part in additive manufacturing involves _____ based manufacturing.

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

    Match the following terms with their descriptions:

    <p>Visualization Tool = Allows viewing and manipulating the part Setup Parameters = Specific to each AM machine and process Semi-Automated Process = Initial stages requiring manual control Manual Finishing = Final preparation before the part is ready for use</p> Signup and view all the answers

    The eight steps in additive manufacturing include conceptualization, CAD, conversion to ______, and machine setup.

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

    Which of the following is NOT a consideration for designing for additive manufacturing (AM)?

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

    Interlocking features can aid in reducing part count in an assembly.

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

    Match the following AM machine types with their characteristics:

    <p>Photopolymer based systems = Use light to cure resin Powder-based systems = Use powder material to create parts layer by layer Molten material systems = Melt material and deposit it to build parts Solid sheets = Join layers of sheets to form the final structure</p> Signup and view all the answers

    What happens if an incorrect setup procedure is performed on an AM machine?

    <p>A part will still be built, but quality may be affected</p> Signup and view all the answers

    Exposure to ____ and excess light should be avoided due to material handling issues.

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

    All machines will alert the user once the building process is complete.

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

    Which application area does NOT typically involve conventional CAD modeling?

    <p>Electronic circuit design</p> Signup and view all the answers

    Part orientation is not important in the design for additive manufacturing.

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

    What is commonly required after parts are built in an AM machine before they are ready for use?

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

    Name one issue related to materials handling in additive manufacturing.

    <p>Material waste or contamination</p> Signup and view all the answers

    Which method is primarily used for photomasks in the microelectronic industry?

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

    In the vector scan approach, recoating is unnecessary.

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

    What type of light is predominantly used in dentistry?

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

    The ___ projection approach utilizes a large radiation beam patterned by a Digital Micromirror Device.

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

    Match the configurations used in photopolymerization processes with their descriptions:

    <p>Vector scan = Point-wise scanning approach typically in commercial machines Mask projection = Layer-wise irradiation of entire layers at once Two-photon = High-resolution point-by-point photography Far UV = Type of radiation used in microelectronics</p> Signup and view all the answers

    Which of the following is a key component of photopolymerization processes?

    <p>Photo initiator systems</p> Signup and view all the answers

    What type of radiation is primarily used to cure most photopolymers?

    <p>Ultraviolet (UV)</p> Signup and view all the answers

    Two-Photon Vat Photopolymerization offers multiple benefits and no drawbacks.

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

    Photopolymers were developed in the 1970s and are used in the printing industry.

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

    What is the purpose of modeling in photopolymerization processes?

    <p>To understand and predict the interactions between laser and resin.</p> Signup and view all the answers

    Who experimented with UV curable materials and is credited with the beginning of stereolithography (SL) technology?

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

    The process of ______ involves exposing layers of liquid resin to UV light to create solid patterns.

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

    In vector scan machines, different __________ patterns like WEAVE and STAR-WEAVE are used for building parts.

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

    Match the following photopolymerization processes with their characteristics:

    <p>Gamma rays = Used for curing commercial photopolymers UV light = Primarily used to cure most photopolymers X-rays = Another type of radiation used in photopolymerization Visible light = Used in some specific photopolymer systems</p> Signup and view all the answers

    Match the following photopolymerization technologies with their characteristics:

    <p>Laser Scan Vat Photopolymerization = Layer-based build phenomenon Mask Projection VP = Utilizes masks to expose resin Two-Photon Vat Photopolymerization = Enables very fine resolutions Vector Scan Micro-Vat = Compact and faster build process</p> Signup and view all the answers

    What type of polymerization is associated with acrylate photopolymers?

    <p>Free radical polymerization</p> Signup and view all the answers

    The recoating system in Vector Scan VP Machines is responsible for lifting the platform after each layer is cured.

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

    Name one type of radiation commonly used to cure photopolymers.

    <p>UV or electron beams</p> Signup and view all the answers

    The main purpose of a photoinitiator in photopolymerization is to convert ______ into reactive intermediates.

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

    Match the following photopolymerization types with their corresponding materials:

    <p>Free radical polymerization = Acrylate Cationic polymerization = Epoxy Vinylether polymerization = Vinylether Both types = Multifunctional monomers</p> Signup and view all the answers

    What is typically done during the finishing phase after building a part using Laser Scan Vat Photopolymerization?

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

    Post-curing is the final step in the Laser Scan Vat Photopolymerization process.

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

    What is the role of multifunctional monomers in photopolymer resin formulation?

    <p>To provide better cross-linking and enhance the mechanical properties of the final product.</p> Signup and view all the answers

    What is one of the main advantages of vat photopolymerization technology over other Additive Manufacturing technologies?

    <p>Accuracy and surface finish</p> Signup and view all the answers

    Current SL materials possess impact strength and durability comparable to high-quality injection molded thermoplastics.

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

    What is the position accuracy in the x-y directions for the atypical point-wise Microsterolithography process?

    <p>0.25 µm</p> Signup and view all the answers

    The minimum size of the unit of hardened polymer is _______ in x, y, z dimensions.

    <p>5 µm x 5 µm x 3 µm</p> Signup and view all the answers

    Which of the following is a recognized drawback of using vat photopolymerization?

    <p>Degraded mechanical properties over time</p> Signup and view all the answers

    Mask projection VP technologies have a speed disadvantage compared to laser scan SL.

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

    What is the maximum size of the fabrication structure achievable through the atypical point-wise Microsterolithography process?

    <p>10 mm x 10 mm x 10 mm</p> Signup and view all the answers

    Study Notes

    Generalized Additive Manufacturing Process Chain

    • Additive Manufacturing (AM) is a process with key steps
    • Steps include conceptualization and CAD, conversion to STL, transfer and manipulation of STL files on AM machines
    • Machine setup, build, part removal and cleanup, post-processing, and application are also involved
    • Variations can occur between different AM machines, influenced by photopolymer, powder-based, and molten material systems. Metal-based systems have variations as well
    • Material properties, including the use of substrates, energy density, weight, accuracy and speed, as well as maintenance of machine equipment and material handling are all important factors in the process
    • Design for AM includes part orientation, support removal, hollowing out parts, including undercuts, reducing part count in an assembly, and using identification markings/numbers

    Eight Steps in AM

    • Conceptualization and CAD: Product design and function are visualized, often through various methods like textual descriptions, sketches, or 3D CAD models.
    • Conversion to STL: CAD models are converted to STL (Stereolithography) files, which describe the model's geometry using triangular facets. This conversion is automatic in most CAD systems.
    • Transfer to AM Machine and STL File Manipulation: STL files are sent to the target machine. Verification, repositioning, or adjustments to accommodate machine tolerances might be needed. This step may involve verification that the part is correct, use of visualization tools for manipulation, repositioning of the part or changing the orientation, and managing multiple parts for a single machine process. Parts may require shrinkage or coating allowance during this phase.
    • Machine Setup: Specific parameters for each AM machine or process are considered, like materials, layer thickness, build parameters. Incorrect settings may affect the part quality. Multiple materials, a variety of layer thickness, and optimization options are common in machine setups, and may require special considerations
    • Build: Mostly semi-automated, with considerable manual control and decision-making involved. Layers are controlled, built, and formed one after the other, combining material deposition. Different approaches are used by different machines
    • Removal and Cleanup: Parts are separated from the build platform or excess build material. Support structure removal might be needed for some designs. Manual finishing is often necessary after this step, including support structure removal.
    • Post-processing: This involves finishing the part for specific applications, using techniques like abrasive finishing, polishing, or coating applications. Specific requirements, like precision, depend on the application. Finishing procedures also may include tubs/ovens for specific materials.
    • Application: After post-processing, parts are ready for use, but characteristics may not always perfectly align with standard material specifications. Possible issues include material degradation, trapped bubbles/materials within parts, anisotropic properties of the material
    • Parts may not always behave according to material standards in subsequent use, such as molding or casting;
    • AM machines may create parts with small voids or bubbles trapped inside. This could be the source of part failure under mechanical stress
    • Some AM processes cause material degradation during build and not to be properly bonded, linked, or crystallized;
    • This can lead to anisotropic (different properties in different directions) properties.
    • AM materials and processes are improving, and many applications may not require high performance
    • The number of applications for AM processes are continually increasing

    Variations from One AM Machine to Another

    • Photopolymer-Based Systems: Easy setup, but less robust materials, and supports can come off easily. Supports can be the same material as the part
    • Powder-Based Systems: Don't need supports; usually easy setup; parts can be colored using colored binder materials
    • Molten Material Systems: These systems use support structures, which are generated automatically, sometimes with user flexibility;
    • Solid Sheets: These systems don't need supports(lamination); waste material and cleanup might be more laborious; bonding of polymer sheets is often reliable

    Material Considerations

    • Metal Systems: Considerations include the use of substrates, energy density, weight, accuracy, and speed.
    • Maintenance of Equipment: Requires careful monitoring and protection from noise or dirt, as well as electrical noise and mechanical vibration
    • Material Handling: Exposure to moisture, excess light should be avoided. Materials might be loaded or unloaded offline using software systems, and recycling might be required
    • Design for AM: Important design aspects for AM include part orientation, handling built-up parts, removal of supports, and features(undercuts). Reducing the parts/assembly count is also helpful
    • Design Consideration in AM - Considerations like interlocking features are necessary for certain parts designs

    Application Considerations

    • AM applications might not align with standard material specifications
    • Issues like trapped material, material degradation, or the anisotropic properties of materials might occur. However, AM applications are expanding rapidly

    Exercises

    • Investigate websites for AM technologies, focusing on each step of the process and any particular tasks
    • Surface models are unsuitable for AM parts, due to the need for accurate geometric representation for creation. Problems like inappropriate resolutions are possible
    • VRML is more suitable than STL for certain applications (e.g., color) for ZCorp printing
    • Consider additional factors (e.g., material properties, design constraints) when creating medical models using AM
    • Explore finishing methods for different material parts (for example, color ZCorp)

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    Related Documents

    Additive Manufacturing Process Chain PDF
    Vat Photopolymerization Processes PDF

    Description

    This quiz explores the various stages of the Additive Manufacturing process, detailing each key step from conceptualization and CAD through to post-processing and application. It also examines variations in methods and material properties that impact production. Perfect for students and professionals looking to deepen their understanding of AM.

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