Generalized AM Process Chain
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Questions and Answers

Which of the following is NOT a key step in the Additive Manufacturing process sequence?

  • Material extraction (correct)
  • Transfer and manipulation of STL file
  • Post-processing of part
  • Conceptualization and CAD

    • The STL file format is used for different AM machine types.

    True

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

    STereoLithography

    The ______ process involves the removal of supports and hollowing out parts to optimize designs for AM.

    <p>Design for AM</p> Signup and view all the answers

    Match the type of AM machine to its characteristic:

    <p>Photopolymer based systems = Use liquid resin and UV light Powder-based systems = Use powdered material and lasers Molten material systems = Utilize thermoplastic filaments Solid sheets = Process layers of solid material</p> Signup and view all the answers

    Which area does NOT typically involve conventional CAD modeling?

    <p>Mechanical CAD design</p> Signup and view all the answers

    Energy density is a critical factor in metal additive manufacturing.

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

    Name one operational issue related to materials handling in additive manufacturing.

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

    What is one common requirement before building a part?

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

    It is common for AM machines to setup a single material with no variation in build parameters.

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

    What do AM machines do after the initial semi-automated stages?

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

    Parts produced by AM machines often require significant amount of manual __________ before they are ready for use.

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

    Match the following actions with their appropriate descriptions:

    <p>Verifying the part = Ensuring the specifications are met Repositioning the part = Adjusting orientation for optimal build Setup parameters = Specific settings for different machines Machine alert = Notification for user action required</p> Signup and view all the answers

    What may some parts require to ensure quality during the additive manufacturing process?

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

    Once a part is built, it is usually ready for immediate use without any finishing.

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

    What is a potential unusual requirement for some STL files?

    <p>Segmentation of STL files.</p> Signup and view all the answers

    What is the purpose of support structures in additive manufacturing (AM)?

    <p>To keep the part from collapsing or warping during the building process</p> Signup and view all the answers

    Post-processing stages in AM are usually automated and do not require manual intervention.

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

    What are some common methods used in the post-processing stage of AM?

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

    AM processes often result in parts that have small voids or ______ trapped inside them.

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

    Match the following terms with their descriptions:

    <p>Support structures = Help prevent warping during building Post-processing = Finishing parts for application Anisotropic properties = Different properties in different directions AM materials = Continuously improving and diversifying applications</p> Signup and view all the answers

    What can result from mishandling parts during support removal in AM?

    <p>Lower quality output</p> Signup and view all the answers

    The properties of parts created through additive manufacturing are typically the same in all directions.

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

    Some applications may not require ______ performance from many components produced through AM.

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

    Which of the following statements about future developments in additive manufacturing is accurate?

    <p>Processes may incorporate both additive and subtractive elements.</p> Signup and view all the answers

    Architectural modeling designs are always exact representations of the final product.

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

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

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

    In lamination methods, supports are required to hold the sheets in place.

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

    What is the purpose of optimizing software for additive manufacturing?

    <p>To improve the efficiency and effectiveness of the additive manufacturing process.</p> Signup and view all the answers

    The technology involving the use of __________ scanning is essential for reverse engineering data.

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

    What factors should be considered when working with metal systems compared to polymer systems?

    <p>Subtracts, energy density, weight, accuracy, speed</p> Signup and view all the answers

    Material handling issues require exposure to ______ and to excess light to be avoided.

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

    Match the following technologies or processes with their description:

    <p>Laser scanning technology = Reverse engineering data acquisition Additive processes = Building up material layers Subtractive processes = Removing material from a part Post-processing techniques = Finishing models after printing</p> Signup and view all the answers

    Match the application areas with their corresponding techniques:

    <p>Medical modeling = CT, MRI, 3D ultrasound Injection molding = High-volume production FDM = Extrusion process Lamination = Sheet cutting and bonding</p> Signup and view all the answers

    Which of the following is NOT an aspect of design for additive manufacturing (AM)?

    <p>Use of conventional CAD modeling</p> Signup and view all the answers

    Careful monitoring of machines is necessary due to fragile laser or printer technology.

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

    Name a method to recycle material from a build that did not form the part.

    <p>Offline loading using software systems</p> Signup and view all the answers

    Study Notes

    Generalized AM Process Chain

    • Consists of eight key steps: Conceptualization and CAD, Conversion to STL, Transfer and Manipulation of STL File on AM Machine, Machine Setup, Build, Part Removal and Cleanup, Post-processing, and Application.
    • Can be applied in various areas including areas that don’t involve conventional CAD modeling, like medical modeling, reverse engineering, and architectural modeling.

    Eight Steps in AM

    • STL (STereoLithography) is a simple way of describing a CAD model in terms of its geometry alone.
    • STL files can be manipulated using specialized software tools.
    • Machine setup parameters are critical for achieving acceptable final quality.
    • The build process involves layer-based manufacturing controlled by a computer.
    • Support structures may be required to prevent parts from collapsing or warping during the build process.
    • Post-processing may involve abrasive finishing, coatings, or other application-specific tasks.
    • AM parts may have different mechanical properties than parts made using conventional manufacturing methods.

    Metal Systems

    • Use of substrates, energy density, weight, accuracy, and speed are important factors to consider.

    Variations Across AM Machines

    • Photopolymer based systems, powder based systems, molten material systems, and solid sheets are examples of AM machine variations.

    Maintenance of Equipment

    • AM machines can be sensitive to dirt, noise (both electrical and mechanical), and moisture.

    Material Handling Issues

    • Materials should be protected from moisture and excess light.
    • Loading material is often done offline using software systems.
    • Recycling of material from failed builds can be effective.

    Design for AM

    • Consider part orientation, removal of supports, hollowing out parts, inclusion of undercuts and other manufacturing constraining features, interlocking features, reduction of part count in an assembly, and identification markings/numbering.

    Interlocking Features

    • Interlocking features can be used to create complex shapes.

    Future Considerations

    • Some AM technologies are moving towards thicker layers or processing regions rather than layers.
    • Color and other forms of multiple material systems are becoming more common.
    • Hybrid technologies that combine additive, subtractive, and robotic handling are being developed.
    • Software is being optimized for AM processing.
    • Standardized software processes based around AM are needed.

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    Related Documents

    Additive Manufacturing Process Chain PDF

    Description

    Explore the eight essential steps of the Additive Manufacturing (AM) process, from conceptualization to application. This quiz covers STL file manipulation, machine setup, building, and post-processing techniques applicable in diverse fields such as medical modeling and architectural design.

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