Generalized Additive Manufacturing Process Chain
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Questions and Answers

What is the first key step in the Additive Manufacturing process chain?

  • Part removal and cleanup
  • Machine setup
  • Post-processing of part
  • Conceptualization and CAD (correct)

STL stands for Standard Triangle Language.

False (B)

Name one application area of Additive Manufacturing that does not involve conventional CAD modeling.

Medical modeling

The Additive Manufacturing process involves _____ and CAD, which is the initial step.

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

Match the following types of Additive Manufacturing systems with their characteristics:

<p>Photopolymer-based systems = Use of liquid resins that harden using ultraviolet light Powder-based systems = Involves layering powder materials to form a solid part Molten material systems = Use of melted material which is deposited layer by layer Solid sheets = Utilizes flat sheets of material that are cut and merged</p> Signup and view all the answers

Which of the following is NOT a factor to consider during the design for Additive Manufacturing?

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

Energy density is an important consideration for metal Additive Manufacturing systems.

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

What does CAD stand for in the context of Additive Manufacturing?

<p>Computer-Aided Design</p> Signup and view all the answers

What is often required when removing support structures from 3D printed parts?

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

Post-processing stages in additive manufacturing often involve automated processes.

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

What is a potential drawback of parts produced through additive manufacturing?

<p>Small voids or bubbles trapped inside the parts</p> Signup and view all the answers

During post-processing, abrasive finishing techniques like _____ and _____ may be utilized.

<p>polishing, sandpapering</p> Signup and view all the answers

Match the following processes with their descriptions:

<p>Abrasive finishing = Polishing and sandpapering Support removal = Manual skill and handling Material degradation = Trapped voids and bubbles Post-processing = Final finishing stages before application</p> Signup and view all the answers

What might happen to parts created by additive manufacturing when subjected to mechanical stress?

<p>They could fail due to trapped voids (B)</p> Signup and view all the answers

All additive manufacturing applications require high-performance components.

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

What is a critical step before building the part?

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

What does anisotropic mean in the context of additive manufacturing parts?

<p>Different properties in different directions</p> Signup and view all the answers

What type of technology is primarily used for reverse engineering data?

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

Only one part can be built at a time using AM machines.

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

What must be done to ensure final part quality in AM processes?

<p>Correct setup procedures must be followed.</p> Signup and view all the answers

Architectural modeling strictly adheres to exact final designs without any modifications.

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

What software is designed to convert World of Warcraft models into a specific format?

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

With AM machines, the process switches to __________ after the first few semi-automated stages.

<p>computer controlled building phase</p> Signup and view all the answers

Match the following AM machine setup characteristics with their descriptions:

<p>Single Material = Few setup parameters and consistent settings Variety of Materials = Numerous setup options requiring optimization Incorrect Setup = Results in unacceptable final quality Segmentation of STL files = Necessary in unusual cases</p> Signup and view all the answers

Processes combining additive and ___ elements represent a trend in modern manufacturing.

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

What is a common practice during the Removal and Cleanup phase?

<p>Parts often require manual finishing (B)</p> Signup and view all the answers

Match the following technologies or processes with their primary characteristics:

<p>Laser scanning technology = Reverse engineering data capture STL file format = Common format for 3D printing Additive manufacturing = Layer-by-layer construction Post-processing techniques = Enhancing the finished product</p> Signup and view all the answers

The machine will notify users when the build is complete or if material is low.

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

Many __________ software tools are available for STL file manipulation.

<p>free or purchased</p> Signup and view all the answers

What is necessary for molten material systems during the melting and depositing process?

<p>Support structures (D)</p> Signup and view all the answers

The maintenance of equipment in 3D printing is not affected by environmental conditions.

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

What must be processed in lamination methods to ensure smooth operation?

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

Exposure to ______ and to excess light should be avoided in material handling.

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

Match the following application areas with their uses:

<p>CT = Medical modeling MRI = Medical imaging 3D ultrasound = Medical diagnostics FDM = Filament-based printing</p> Signup and view all the answers

Which of the following is a key consideration for metal systems?

<p>High energy density (A)</p> Signup and view all the answers

Droplet-based systems like the Thermojet process do not require support structures.

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

List one advantage of reducing part count in an assembly.

<p>Lower assembly costs</p> Signup and view all the answers

What is the nominal layer thickness for most FDM Dimension machines?

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

Using thicker layers in additive manufacturing always increases precision.

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

Name one disadvantage of photopolymer-based systems in additive manufacturing.

<p>Poor mechanical properties.</p> Signup and view all the answers

In powder-based systems, there is _____ need to use supports.

<p>no</p> Signup and view all the answers

Match the following additive manufacturing technologies with their characteristics:

<p>Photopolymer-Based Systems = Good accuracy with thin layers but poor mechanical properties Powder-Based Systems = Layer-by-layer build without need for supports Droplet Deposition = Supports can be modified during printing Binder Printing = Allows for colored parts using binder material</p> Signup and view all the answers

What can fine details in a design cause problems with in additive manufacturing?

<p>All of the above (D)</p> Signup and view all the answers

Newer resins in photopolymer systems do not need UV protective coatings.

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

What type of material is processed in powder-based systems?

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

Flashcards

Conceptualization & CAD

The initial stage where you imagine and design the product, often using 3D modeling software like CAD.

Conversion to STL

The process of transforming your CAD model into a standard file format called STL (STereoLithography), which represents the shape using triangles.

Transfer & STL Manipulation

Moving the STL file to the 3D printer and making any necessary adjustments to the design before the actual printing process.

Machine Setup

Preparing the 3D printer for the printing process, including calibrating settings and loading the appropriate materials.

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Build

The actual printing process where the 3D printer layer by layer creates the final product based on the STL file.

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Part Removal & Cleanup

Extracting the printed part from the 3D printer and removing any supporting structures or excess material.

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Post-processing

Applying additional treatments to the printed part, such as smoothing, painting, or strengthening, to achieve the desired final product.

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Application

The final stage where the printed part is used for its intended purpose, such as a prototype, a tool, or a final product.

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Part Verification

Checking if the part's design is accurate and ready for printing.

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Visualization Tool

Software used to view and manipulate 3D models, allowing adjustments before printing.

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Part Repositioning

Moving or rotating the part within the 3D printer's build space for optimal placement.

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Multiple Part Builds

Printing more than one part simultaneously, either identical copies or different designs.

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Shrinkage & Coating Allowances

Adjustments made to the design to account for material shrinkage or coating thickness during printing.

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STL File Segmentation

Dividing large or complex 3D models into smaller parts to enable easier printing.

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Machine Setup Parameters

Settings specific to the 3D printer, material, and desired print quality.

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Build Phase Stages

The process of creating the 3D object layer by layer, starting with a semi-automated setup and transitioning to fully automated printing.

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Layer Thickness & Precision

The thickness of each layer affects the print speed and precision. Thicker layers are faster but less precise.

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Material Choice Impact

Different materials used in 3D printing require varying processing times, resources, and expertise.

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Post-Processing Considerations

Activities like heat treatment or machining require knowledge of the material's properties (heat resistance, strength, etc.).

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Powder-Based Systems: Support Structures

Powder-based 3D printing often does not require support structures since the powder itself provides a base.

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Photopolymer Vat: Support Material

In liquid vat photopolymer systems, support structures must be made of the same material as the printed part.

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Droplet Deposition: Support Flexibility

Droplet deposition allows for variable support materials, making removal easier.

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Photopolymer Strengths & Weaknesses

Photopolymer systems offer good accuracy but generally have weaker mechanical properties compared to other AM materials.

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Zcorp. Binder Printing

A unique feature of Zcorp. binder printing allows creating colored parts by using colored binder material.

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Support Structures

Temporary structures added during the 3D printing process to prevent parts from collapsing or warping. They are usually removed after the printing is complete.

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Post-processing, why?

The finishing stage where parts are cleaned, smoothed, or coated to meet specific application needs. This step makes them ready for their intended use.

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Anisotropic Properties

Materials exhibiting different properties in different directions. This is a common characteristic of 3D printed parts due to the layer-by-layer build process.

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AM Application Growth

The number of applications for 3D printed parts is constantly increasing as the technology improves and its applications become more widespread.

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Post-Processing Complexity

The amount of post-processing required can vary greatly depending on the part's application. Some parts need minimal finishing, while others require careful handling and specialized tools.

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Reverse Engineering Data

Using laser scanning technology to capture the precise dimensions and geometry of an existing object, creating a digital representation of its shape.

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Architectural Modeling

Creating 3D models of buildings or structures, often incorporating textures, colors, and realistic details to visualize the final design.

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Thicker Layers

Some 3D printing technologies are moving towards using thicker layers of material, improving printing speed and reducing production time.

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Multiple Materials

The future of 3D printing includes the use of various materials in a single print, creating objects with different properties and colors.

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Hierarchical Design

Describing 3D objects in a structured format where parts are assembled into larger components, enabling complex designs with intricate details.

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Study Notes

Generalized Additive Manufacturing Process Chain

  • Additive Manufacturing (AM) is a process chain
  • Key steps in the process sequence:
    • Conceptualization and CAD
    • Conversion to STL
    • Transfer to AM machine and STL file manipulation
    • Machine setup
    • Build
    • Part removal and cleanup
    • Post-processing
    • Application
  • Variation from one AM machine to another:
    • Photopolymer systems
    • Powder-based systems
    • Molten material systems
    • Solid sheets
    • Metal systems
    • Use of substrates, energy density, weight, accuracy, and speed
  • Maintenance of equipment
  • Materials handling issues
  • Design for AM:
    • Part orientation
    • Removal of supports
    • Hollowing out parts
    • Inclusion of undercuts and other constraining features
    • Interlocking features
    • Reduction of part count in an assembly
    • Identification markings/numbers

Eight Steps in AM

  • Conceptualization and CAD:
    • Conceptual ideas for product look and function.
    • Can include textual descriptions, sketches, and 3D CAD models.
  • Conversion to STL:
    • STL (Stereolithography) file format describes a CAD model's geometry.
    • Uses triangular facets to approximate the model's surface.
    • Conversion to STL is automatic in most CAD systems.
  • Transfer to AM Machine and STL File Manipulation:
    • STL file is transferred to the AM machine.
    • Part may require verification, repositioning, or adjustments.
  • Machine Setup:
    • AM machines have specific setup parameters.
    • Some machines are designed for single or few materials and no variation.
    • Others accommodate multiple materials and optimization options.
  • Build:
    • Semi-automated initial stages requiring manual intervention.
    • Computer-controlled layer-by-layer manufacturing using a platform and material deposition.
    • Machine repeats process until build complete or material runs out.
  • Removal and Cleanup:
    • Part separation from build platform or excess build material.
    • AM machines may use support structures for added stability.
    • Manual finishing and support removal are often necessary.
  • Post-processing:
    • Manual finishing processes (polishing, sandpapering) or coatings may be required.
    • Precision, quality, and application-specific finishing are key.
  • Application:
    • Finished parts may not always behave as expected (e.g., in molding/casting)
    • AM may create parts with trapped voids.
    • Some AM processes may create anisotropy (different properties in different directions).
    • Applications for AM outputs (e.g., parts in devices) are constantly increasing.

Variations from One AM Machine to Another

  • Photopolymer Systems:
    • Easy setup (liquid vat systems).
    • Uses materials.
    • Some support removal issues.
  • Powder-Based Systems:
    • No support structures needed.
    • Layers built with powder beds, often enabling color options.
  • Molten Material Systems:
    • Support structures can be automatic or manual
    • Extrusion or droplet-based processing
  • Solid Sheets:
    • Lamination techniques can create parts.
    • Waste management issues.
    • Polymer sheet bonding is relatively stable.

Maintenance of Equipment & Material Handling

  • Fragile laser and printer technologies need careful handling.
  • Exposure to moisture and light for materials must be managed.
  • Offline material loading and recycle protocols should be developed.

Design for Additive Manufacturing

  • Part orientation
  • Support removal
  • Hollowing out parts
  • Inclusion of undercuts/constraining features
  • Interlocking features
  • Reduction of part count
  • Identification marking/numbering

Exercise Summary

  • Investigate AM-related websites for process handling and result analysis.
  • Explain why surface modeling is unsuitable for AM design and possible errors when using solely surface modeling techniques.
  • Evaluate VRML for color model specifications in AM printing machines.
  • Analyze unique considerations for medical AM designs compared to generic products.
  • Examine finishing techniques applicable to a color-printed AM part.

Application Areas

  • Modeling techniques beyond traditional CAD, like medical, reverse engineering data, and architectural modeling.
  • Further discussions on expanding layer thickness and material types/color, as well as describing models outside the STL format.

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Additive Manufacturing Process Chain PDF

Description

Explore the comprehensive process chain of Additive Manufacturing (AM) through this quiz. Learn about key steps such as conceptualization, CAD design, machine setup, and post-processing. Understand the variations and considerations that different AM systems present for effective manufacturing.

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