Introduction to Additive Manufacturing (AM)
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What is one major benefit of additive manufacturing (AM)?

  • Requires more design revisions
  • Eliminates prototype testing
  • Reduces engineering changes (correct)
  • Increases production time

    • The cost of engineering changes remains the same during all stages of development.

    False

    Name one type of technology used in rapid prototyping.

    Fused Deposition Modeling (FDM)

    The ____________ technology is known for enhancing precision in 3D printing.

    <p>Selective Laser Sintering (SLS)</p> Signup and view all the answers

    Match the following rapid prototyping technologies with their descriptions:

    <p>Fused Deposition Modeling = Layering molten material Selective Laser Sintering = Using a laser to fuse powder particles StereoLithography Apparatus = Utilizing UV light to cure resin 3D Systems ProJet = Inkjet technology for 3D printing</p> Signup and view all the answers

    Which of these is NOT a stage in the development process where engineering change costs increase?

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

    What is one characteristic that differentiates AM technologies from CNC machining?

    <p>Additive manufacturing builds objects layer by layer, while CNC machining typically removes material.</p> Signup and view all the answers

    Reverse engineering software performs similar functions as conventional 3D CAD software.

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

    What is the primary distinction between additive manufacturing and CNC machining?

    <p>Additive manufacturing builds components layer by layer.</p> Signup and view all the answers

    Additive manufacturing is synonymous with subtractive manufacturing.

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

    What does AM stand for in the context of manufacturing?

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

    In the additive manufacturing process, a component is built __________ by depositing material.

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

    Match the following terms related to additive manufacturing with their definitions:

    <p>Stereolithography = A technique that uses a laser to cure liquid resin into hardened plastic Rapid Prototyping = The fast fabrication of a physical part using 3D CAD data 3D Printing = A widely used term that refers to various additive manufacturing technologies Additive Fabrication = The general term for any process that builds objects layer by layer</p> Signup and view all the answers

    Which of the following materials can be used in additive manufacturing?

    <p>Fine powder metals</p> Signup and view all the answers

    Automated fabrication is a term that can be used to describe additive manufacturing.

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

    What is the primary benefit of additive manufacturing compared to conventional methods?

    <p>It allows for the creation of complex geometries more easily.</p> Signup and view all the answers

    Which technology plays a crucial role in the development of Additive Manufacturing (AM)?

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

    Additive manufacturing technology only uses liquid polymer systems for creating products.

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

    What is the main distinction between additive manufacturing and traditional machining methods?

    <p>Additive manufacturing builds objects layer by layer while traditional machining removes material from a solid block.</p> Signup and view all the answers

    The classification of AM processes includes systems like liquid polymer systems, solid sheet systems, and __________.

    <p>molten material systems</p> Signup and view all the answers

    Match the following features of computer technology with their associated roles in additive manufacturing:

    <p>Processing power = Real-time control of machines Graphics capability = Visualization of 3D models Networking = Integration of multiple systems Integration = Seamless communication between technologies</p> Signup and view all the answers

    Which of the following is a future trend in additive manufacturing?

    <p>Expansion of direct digital manufacturing</p> Signup and view all the answers

    Name one component of Computer-Aided Manufacturing (CAM) technologies.

    <p>Numerically Controlled (NC) machines</p> Signup and view all the answers

    NURBS can be classified under Computer-Aided Design technologies.

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

    Which of the following is NOT a category for classifying additive manufacturing processes?

    <p>Laser Cutting Systems</p> Signup and view all the answers

    Computer-Aided Design (CAD) technology has seen improvements in usability and user interface.

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

    Name one technology used in additive manufacturing that involves laser energy.

    <p>Electron Beam Melting (EBM)</p> Signup and view all the answers

    The __________ technology utilizes a container filled with powder that is processed using an energy source.

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

    Match the following additive manufacturing processes with their descriptions:

    <p>Material Extrusion = Deposits material by extruding it through a nozzle Binder Jetting = Prints binder into a powder bed Sheet Lamination = Deposits layers of material in sheet form Directed Energy Deposition = Simultaneously deposits material and provides energy</p> Signup and view all the answers

    Which of the following is a future trend in additive manufacturing?

    <p>Direct Digital Manufacturing</p> Signup and view all the answers

    Laser-Engineered Net Shaping (LENS) is categorized under AM metal systems.

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

    What does CAD stand for in the context of engineering technology?

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

    Study Notes

    Introduction to Additive Manufacturing (AM)

    • AM is a process where a 3D digital model is used to build a product layer by layer by depositing material
    • The term 3D printing is increasingly used as a synonym for AM
    • Instead of removing material from a solid block (like CNC machining), AM builds components layer by layer using materials in powder form
    • AM also utilizes a wide range of materials, such as metals, plastics, and composites

    Why Use the Term Additive Manufacturing?

    • It's a more accurate term for a professional production technique

    Benefits of AM

    • Reduces Engineering Changes: The cost of making changes increases drastically as a project progresses, making AM beneficial for early design iterations
    • Rapid Prototyping: AM allows for the quick creation of prototypes, making it extremely valuable for rapid development cycles

    Distinction Between AM and CNC Machining

    • Material: AM uses materials in powder form, while CNC machining typically uses solid blocks
    • Speed: Generally, AM is slower than CNC machining, especially for large-scale production runs
    • Complexity: AM excels in creating complex geometries, while CNC machining becomes more challenging for intricate designs
    • Accuracy: Modern AM processes can achieve high accuracy
    • Geometry: AM offers greater flexibility in complex shapes and internal cavities, while CNC machining is limited by tool path constraints
    • Programming: AM requires a 3D model, while CNC machining requires detailed tool paths

    Examples of AM Parts

    • AM enables the creation of intricate geometries not possible with traditional manufacturing methods
    • Reverse Engineering: This process uses 3D scanning and software to recreate a digital model from a physical object
    • Computer-Aided Engineering (CAE): CAE uses simulation software to analyze the performance of designs before manufacturing
    • Haptic-based CAD: Haptic feedback allows users to interact with 3D models more realistically, enhancing design and manipulation

    Additive Manufacturing Technology Development

    • AM technology leverages computer technology for processing power, graphics, machine control, networking, and integration.
    • Computer-aided design (CAD) plays a crucial role in AM, particularly 3D solid modeling software.
    • Layer-based AM technology is fundamental to the process.
    • Computer-aided manufacturing (CAM) uses NC and CNC machines for part fabrication, often requiring multiple passes and setups.
    • Computer-aided engineering (CAE) and finite element analysis (FEA) are also integral to AM.
    • CAD technology has advanced in terms of realism, usability, engineering content, speed, accuracy, complexity, and usability.
    • STL file format is commonly used in AM, representing surfaces with triangles described by points and facet normal vectors.

    Associated Technologies

    • Lasers, printing technologies, programmable logic controllers (PLCs), materials, and CNC machining are key associated technologies in AM.
    • Layer-by-layer fabrication is a defining characteristic of AM processes.

    Classification of AM Processes

    • Liquid Polymer Systems: Utilize liquid photopolymers cured selectively using energy.
    • Discrete Particle Systems: Processes involve powders selectively fused using an energy source.
    • Molten Material Systems: Processes use molten materials, deposited and solidified in layers.
    • Solid Sheet Systems: Processes employ sheets of material layered and bonded together.

    New AM Classification Schemes

    • Vat Photopolymerization: Liquid photopolymers are selectively cured in a vat.
    • Powder Bed Fusion: Powder is selectively fused using energy sources like lasers or electron beams.
    • Material Extrusion: Materials are extruded through a nozzle in a pattern to create cross-sections.
    • Material Jetting: Ink-jet printing processes are employed for material deposition.
    • Binder Jetting: A binder is printed into a powder bed to form cross-sections.
    • Sheet Lamination: Sheets of material are layered and bonded together.
    • Directed Energy Deposition: Material deposition (powder or wire) and processing are simultaneous using a single deposition device.

    Future of Additive Manufacturing

    • Metal Systems: Examples include Laser-Engineered Net Shaping (LENS) and Electron Beam Melting (EBM).
    • Hybrid Systems: Shaped Deposition Manufacturing (SDM) is a prominent example.
    • Milestones in AM Development: Significant milestones include Laminated Object Manufacturing, 3D printing, Selective Laser Sintering (SLS), and Fused Deposition Modeling (FDM).
    • AM Around the World: Early patents originated in Europe (France), USA, and Asia (Japan). Notable companies are from Germany, Netherlands, Sweden, Korea, China, and Israel (Cubital).
    • Future: Rapid prototyping is evolving into direct digital manufacturing (DDM), with rapid manufacturing (RM) playing a vital role.

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    Related Documents

    Additive Manufacturing: Chapter 1 PDF
    Chapter 2 Development of AM Technology PDF

    Description

    This quiz covers the fundamentals of Additive Manufacturing (AM), highlighting its processes, benefits, and distinctions from CNC machining. Explore how AM allows for rapid prototyping and cost-effective engineering changes by building products layer by layer. Gain insights into the materials used and why AM is a preferred term for professionals in the field.

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