Additive Manufacturing

Question 1

The key concept of Additive Manufacturing is that the process ___________ parts gradually under full ___________

Answer 1

builds up, digital control

Question 2

Early materials were low-quality ___________, but principle has advanced to the point where high quality ___________, _______ and _______ are being used

Answer 2

plastics, polymers, metals, ceramics

Question 3

AM offers very good _____________and requires ______ product-specific parts the underlying technology was invented in the ____________

Answer 3

Form freedom, no, 1980s

Question 4

Typical AM layer thickness is ______________

Answer 4

100 Micrometers

Question 5

A CAD model is exported into a “____________________________” (STL) file which represents the boundary of the material as _______

Answer 5

Standard Tessellation language, Triangles

Question 6

What standard is used to classify AM terminology?

Answer 6

ASTM

Question 7

The Seven Sub Principles of AM are:
1. ________________
2. ________________
3. ________________
4. ________________
5. ________________
6. ________________
7. ________________

Answer 7

Powder bed fusion, Vat photo-polymerization, material jetting, material extrusion, sheet lamination, binder jetting, direct energy deposition.

Question 8

What is the most important AM method for manufacturing?

Answer 8

Powder Bed Fusion

Question 9

A powder bed fusion company called _______ is the leader in the technology and calls their process “_________________________”

Answer 9

EOS, Direct metal laser sintering,

Question 10

___________ involves joining materials together by heating them to a point below their melting temperature

Answer 10

Sintering

Question 11

In Powder Bed Fusion, The ____________ powder remains in place, can serve as support, and can be easily ___________ after the process

Answer 11

un-sintered, removed

Question 12

In Powder Bed Fusion, surface properties are generally _______ and __________

Answer 12

grainy, rough,

Question 13

Powder Bed Fusion parts can be used in _____________ applications, but material properties are not as good as in parts made using traditional methods

Answer 13

Load Bearing

Question 14

What AM process is the oldest? (1986)

Answer 14

Vat photo-polymerization

Question 15

Vat photo-polymerization is also known as_________________

Answer 15

Stereo-Lithography

Question 16

_________________ is Similar to Powder bed Fusion but instead uses a ____________ to cure a monomer dissolved in a solvent.

Answer 16

Vat photo-polymerization, UV Laser

Question 17

Compared to powder bed
fusion, Vat photo-polymerization offers:
o _________________
o _________________
o _________________

Answer 17

Higher quality surfaces, Faster process times, Cheaper Equipment

Question 18

In ___________________ individual droplets of
material are deposited _________________

Answer 18

Material Jetting, layer by layer

Question 19

The main company producing Material Jetting is ________

Answer 19

Objet

Question 20

Material Jetting typical has 2 ______ and uses a Viscous ________________________ resin that is cured with high intensity UV light

Answer 20

Heads, Thermosetting

Question 21

What is Material Jetting’s main advantage?

Answer 21

Ability to combine materials (Requires 3 heads)

Question 22

What AM method is the most common method for DIY and home use?

Answer 22

Material Extrusion

Question 23

___________________uses a roll of thin sheet material that is coated with an adhesive. Successive layers are then cut out in a desired Shape and Stacked to build the part

Answer 23

Sheet Lamination

Question 24

In Sheet lamination, input materials can theoretically be ________, ________ or even _________, but so far the only available commercial equipment operates on paper. The process can create large parts, but surface finish is poor and the process creates a lot of waste.

Answer 24

paper, plastic, metal

Question 25

In ___________________ , a liquid adhesive is selectively applied to join powder materials such as _________ or _________

Answer 25

Binder Jetting, gypsum, starch

Question 26

The key company developing Binder Jetting
technology is ____________

Answer 26

zPrinter

Question 27

Binder Jetting products are ___________ and mostly used for ___________. The term “3D printing” used to apply to only this process

Answer 27

semi-structural, mockups

Question 28

_______________ deposits the material at the same time that it __________ it together and eliminates the need for _______________ and manufacturing in horizontal layers.

Answer 28

Direct Energy Deposition, Sinters, powder beds

Question 29

_____________________ offers the ability to add onto existing parts and has very good material properties and no porosity

Answer 29

Direct Energy Composition

Question 30

______________ is where material properties in horizontal direction are _________ than vertical direction

Answer 30

anisotropy, different

Question 31

How does anisotropy affect AM?

Answer 31

Properties within the layers are different than properties between the layers

Question 32

What are the 4 challenges of AM?

Answer 32

Material Anisotropy, Varying Cad files, Part Certification, Cost

Question 33

AM has been used to supply temporary, small volume and highly optimized parts and is being considered for making __________ parts in the field.

Answer 33

spare