Introduction to Additive Manufacturing and Rapid Prototyping
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What is the primary classification of Rapid Prototyping Systems based on?

  • The application of the prototype
  • The method of prototyping
  • The type of material used in the final product
  • The initial form of its material (correct)

    • What is the process used to convert liquid into solid state in liquid-based RP systems?

  • Fusing
  • Curing (correct)
  • Melting
  • Sintering

    • What is the material used in Laminated Object Manufacturing (LOM) prototyping technology?

  • Photopolymer
  • Thermoplastics
  • Titanium alloys
  • Paper (correct)

    • What is the type of laser used in the Laser Engineered Net Shaping (LENS) process?

    <p>Nd: YAG laser</p> Signup and view all the answers

    What is the environment in which the fabrication process takes place in the LENS process?

    <p>Low-pressure argon chamber</p> Signup and view all the answers

    What is the primary purpose of the motion system in the LENS process?

    <p>To move the laser beam horizontally and laterally</p> Signup and view all the answers

    What is the purpose of tilting the object/cluster by 10 to 15 degrees in LOM, SLS, SGC, and 3D printing?

    <p>To avoid any surface becoming horizontal</p> Signup and view all the answers

    What is the primary function of the hot roller in the LOM process?

    <p>To stick the paper layer to the previous layer</p> Signup and view all the answers

    What is a major limitation of the LOM process?

    <p>Grid cutting takes much more time than object cutting</p> Signup and view all the answers

    What is the primary difference between 3D printing and SLS?

    <p>The use of a binder liquid in 3D printing</p> Signup and view all the answers

    What is the function of the nozzle in FDM?

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

    Why are explicit support structures required in FDM?

    <p>To provide additional support for the model</p> Signup and view all the answers

    What is a major advantage of the LENS process?

    <p>Production of fully dense metal parts with superior material properties</p> Signup and view all the answers

    What is a limitation of the DMD process?

    <p>Limited to producing only metal parts</p> Signup and view all the answers

    What is a benefit of the DLD process?

    <p>Ability to add material to existing components for service and repair</p> Signup and view all the answers

    What is a drawback of building overhang parts using traditional DLD or RP processes?

    <p>Support structures are very often needed</p> Signup and view all the answers

    What is a challenge of the 'Cut and then paste' approach in LOM?

    <p>Handling the cut pieces is difficult</p> Signup and view all the answers

    What is an advantage of the 'Paste and then cut' approach in LOM?

    <p>Handling is easy</p> Signup and view all the answers

    What is the primary goal of companies in the current marketplace?

    <p>To respond quickly to changing customer demands</p> Signup and view all the answers

    What is a prototype?

    <p>A model from which further models and eventually the final product will be derived</p> Signup and view all the answers

    What is the term 'rapid prototyping' referring to?

    <p>A process for rapidly creating a system or part representation</p> Signup and view all the answers

    What are alternative names for Rapid Prototyping?

    <p>Additive Manufacturing, Layer Manufacturing, Direct CAD Manufacturing, Solid Freeform Fabrication</p> Signup and view all the answers

    What is the main difference between traditional prototyping and rapid prototyping?

    <p>The time consumed in the process</p> Signup and view all the answers

    What is the main advantage of rapid prototyping over traditional prototyping?

    <p>It gives better quality</p> Signup and view all the answers

    What is the primary method of depositing material in the Fused Deposition Modeling process?

    <p>Small droplets are shot by a nozzle onto a previously formed layer</p> Signup and view all the answers

    What is a major advantage of Fused Deposition Modeling over other RP processes?

    <p>It can be used in an office environment and is very easy to use</p> Signup and view all the answers

    What is a limitation of Electron Beam Melting (EBM) compared to other Powder Bed Fusion (PBF) processes?

    <p>It can only be used with metal powders and has a larger heat-affected zone</p> Signup and view all the answers

    What is the primary difference between Electron Beam Melting (EBM) and other Powder Bed Fusion (PBF) processes?

    <p>EBM uses an electron beam to fuse powder particles, whereas other PBF processes use a laser beam</p> Signup and view all the answers

    What is the purpose of the small mirror in the Selective Laser Sintering (SLS) process?

    <p>To position the laser beam and deflect it in two directions</p> Signup and view all the answers

    Why is it not necessary to use explicit support structures in Selective Laser Sintering (SLS)?

    <p>Because the powder itself acts as support and allows for complex geometries</p> Signup and view all the answers

    What is the purpose of using an inert environment in the selective laser sintering process?

    <p>To minimize fire hazards due to the high activation of fine particles</p> Signup and view all the answers

    What is the advantage of using selective laser sintering over other rapid prototyping techniques?

    <p>It is suitable for making injection molding tools</p> Signup and view all the answers

    What is the purpose of copper impregnation in the selective laser sintering process?

    <p>To improve the polishability of the part</p> Signup and view all the answers

    What is the limitation of selective laser sintering in terms of surface finish?

    <p>It is dependent on the particle size of the powder</p> Signup and view all the answers

    What is the purpose of the small mirror in the stereo lithography process?

    <p>To position the laser beam</p> Signup and view all the answers

    What is the purpose of the post-cure apparatus in the stereo lithography process?

    <p>To complete the polymerization of the part</p> Signup and view all the answers

    What is the pattern used for area filling in the stereo lithography process?

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

    What is the purpose of the contra-rotating roller in the selective laser sintering process?

    <p>To level the layer of powder</p> Signup and view all the answers

    What is the advantage of using stereo lithography over other rapid prototyping techniques?

    <p>It has very low inertia and hence high speed and accuracy</p> Signup and view all the answers

    What is the purpose of the support structures in the stereo lithography process?

    <p>To provide additional support to the part during fabrication</p> Signup and view all the answers

    Study Notes

    Introduction to Rapid Prototyping

    • Rapid prototyping (RP) is a class of technologies that create physical models from Computer-Aided Design (CAD) data.
    • Alternative names for RP include Additive Manufacturing, Layer Manufacturing, Direct CAD Manufacturing, and Solid Freeform Fabrication.

    Traditional Prototyping vs. Rapid Prototyping

    • Traditional prototyping involves building a model from clay, carving from wood, bending wire, or using thermoplastic, photopolymer, metals, paper, or titanium alloys.
    • Traditional prototyping methods are time-consuming, lack quality, and cannot effectively evaluate alternative design concepts.
    • Rapid prototyping methods are faster, more accurate, and can effectively evaluate design concepts.

    Classification of Rapid Prototyping Systems

    • RP systems can be classified into three categories: liquid-based, solid-based, and powder-based.

    Liquid-Based RP Systems

    • Liquid-based RP systems include:
      • 3D Systems' Stereo lithography Apparatus (SLA)
      • Cubital's Solid Ground Curing (SGC)
      • Sony's Solid Creation System (SCS)
      • CMET's Solid Object Ultraviolet-Laser Printer (SOUP)
      • Autostrade's E-Darts
      • Teijin Seiki's Soliform System
      • Meiko's Rapid Prototyping System for the Jewelry Industry
      • Denken's SLP
      • Mitsui's COLAMM
      • Fockele & Schwarze's LMS
      • Light Sculpting
      • Aaroflex
      • Rapid Freeze
      • Two Laser Beams
      • Micro fabrication

    Additive Manufacturing Techniques

      1. Laser Engineered Net Shaping (LENS)
      • Builds components in an additive manner from powdered metals using a Nd:YAG laser.
      • Produces fully dense metal parts with good metallurgical properties.
      • Advantages: superior material properties, complex parts, and reduced post-processing requirements.
      • Disadvantages: limited materials, large physical unit size, and high power consumption.
      1. Direct Metal Deposition (DMD)
      • Uses a laser to weld air-blown streams of metallic powders into custom parts.
      • Can produce fully dense metal parts with good metallurgical properties.
      • Advantages: ability to fabricate fully dense metal parts, efficient, and reduces production costs.
      • Disadvantages: limited to building overhang parts and requires support structures.
      1. Sheet Lamination (Laminated Object Manufacturing (LOM)
      • Builds parts by laminating layers of paper or other materials.
      • Advantages: fast, inexpensive, and ideal for patterns for casting.
      • Limitations: grid cutting takes time, decubing is time-consuming, and horizontal surfaces pose problems.
      1. 3D Printing
      • Similar to SLS, except that a binder liquid is sprayed in selected regions.
      • Can use a wide variety of powders.
      • Advantages: fast, inexpensive, and ideal for concept models.
      • Limitations: requires sintering, and supports are required.
      1. Fused Deposition Modeling (FDM)
      • Uses molten material to build parts.
      • Advantages: uses any thermoplastic material, easy to remove support, and inexpensive.
      • Limitations: slow, not very accurate, and requires explicit support structures.
      1. Electron Beam Melting (EBM)
      • Uses an electron beam to induce fusion between metal powder particles.
      • Advantages: fast, efficient, and can process conductive materials.
      • Limitations: can only be used with conductive materials, and has a larger heat-affected zone.
      1. Selective Laser Sintering (SLS)
      • Uses a laser to fuse together metal powder particles.
      • Advantages: fast, uses a wide variety of powders, and ideal for making injection molding tools.
      • Limitations: surface finish is poor, and Z accuracy is poor.
      1. Photopolymerization (Stereo Lithography (SLA)
      • Uses a laser to polymerize liquid photopolymer.
      • Advantages: fast, accurate, and ideal for making prototypes.
      • Limitations: requires explicit support structures, and post-processing is required.

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    Learn about the basics of additive manufacturing, rapid prototyping, and its applications, limitations, and classification. Compare traditional prototyping with rapid prototyping.

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